Aerosol delivery device with conductive inserts

ABSTRACT

The present disclosure provides aerosol delivery devices. In an example implementation, an aerosol delivery device comprises an aerosol source member that defines an outer surface and an interior area and includes a substrate material having an aerosol precursor composition associated therewith, a control body having a housing that is configured to receive the aerosol source member, an electrical energy source coupled with the housing, and a heating assembly operatively connected to the electrical energy source. The heating assembly includes a plurality of spikes that may be configured to articulate between a retracted position, in which the plurality of spikes is not in contact with the aerosol source member, and a heating position, in which the plurality of spikes pierces through the outer surface of the substrate material and into a portion of the interior area thereof.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/142,558, filed on Sep. 26, 2018, titled AEROSOL DELIVERY DEVICE WITHCONDUCTIVE INSERTS, the content of which is incorporated herein byreference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol delivery articles and usesthereof for yielding tobacco components or other materials in inhalableform. More particularly, the present disclosure relates to an aerosoldelivery device that utilizes electrically-generated heat to heat atobacco or non-tobacco material, preferably without significantcombustion, in order to provide an inhalable substance in the form of anaerosol for human consumption.

DESCRIPTION OF RELATED ART

Many smoking articles have been proposed through the years asimprovements upon, or alternatives to, smoking products based uponcombusting tobacco. Exemplary alternatives have included devices whereina solid or liquid fuel is combusted to transfer heat to tobacco orwherein a chemical reaction is used to provide such heat source.Examples include the smoking articles described in U.S. Pat. No.9,078,473 to Worm et al., which is incorporated herein by reference inits entirety.

The point of the improvements or alternatives to smoking articlestypically has been to provide the sensations associated with cigarette,cigar, or pipe smoking, without delivering considerable quantities ofincomplete combustion and pyrolysis products. To this end, there havebeen proposed numerous smoking products, flavor generators, andmedicinal inhalers which utilize electrical energy to vaporize or heat avolatile material, or attempt to provide the sensations of cigarette,cigar, or pipe smoking without burning tobacco to a significant degree.See, for example, the various alternative smoking articles, aerosoldelivery devices and heat generating sources set forth in the backgroundart described in U.S. Pat. No. 7,726,320 to Robinson et al.; and U.S.Pat. App. Pub. Nos. 2013/0255702 to Griffith, Jr. et al.; and2014/0096781 to Sears et al., which are incorporated herein by referencein their entireties. See also, for example, the various types of smokingarticles, aerosol delivery devices and electrically powered heatgenerating sources referenced by brand name and commercial source inU.S. Pat. App. Pub. No. 2015/0220232 to Bless et al., which isincorporated herein by reference in its entirety. Additional types ofsmoking articles, aerosol delivery devices and electrically powered heatgenerating sources referenced by brand name and commercial source arelisted in U.S. Pat. App. Pub. No. 2015/0245659 to DePiano et al., whichis also incorporated herein by reference in its entirety. Otherrepresentative cigarettes or smoking articles that have been describedand, in some instances, been made commercially available include thosedescribed in U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. Nos.4,922,901, 4,947,874, and 4,947,875 to Brooks et al.; U.S. Pat. No.5,060,671 to Counts et al.; U.S. Pat. No. 5,249,586 to Morgan et al.;U.S. Pat. No. 5,388,594 to Counts et al.; U.S. Pat. No. 5,666,977 toHiggins et al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No.6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No.6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S.Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S.Pat. No. 7,726,320 to Robinson et al.; U.S. Pat. No. 7,896,006 toHamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat. App. Pub. No.2009/0095311 to Hon; U.S. Pat. App. Pub. Nos. 2006/0196518,2009/0126745, and 2009/0188490 to Hon; U.S. Pat. App. Pub. No.2009/0272379 to Thorens et al.; U.S. Pat. App. Pub. Nos. 2009/0260641and 2009/0260642 to Monsees et al.; U.S. Pat. App. Pub. Nos.2008/0149118 and 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub. No.2010/0307518 to Wang; and PCT Pat. App. Pub. No. WO 2010/091593 to Hon,which are incorporated herein by reference in their entireties.

Representative products that resemble many of the attributes oftraditional types of cigarettes, cigars or pipes have been marketed asACCORD® by Philip Morris Incorporated; ALPHA™, JOYE 510™ and M4™ byInnoVapor LLC; CIRRUS™ and FLING™ by White Cloud Cigarettes; BLU™ byFontem Ventures B.V.; COHITA™, COLIBRI™, ELITE CLASSIC™, MAGNUM™,PHANTOM™ and SENSE™ by EPUFFER International Inc.; DUOPRO™, STORM™ andVAPORKING® by Electronic Cigarettes, Inc.; EGAR™ by Egar Australia;eGo-C™ and eGo-T™ by Joyetech; ELUSION™ by Elusion UK Ltd; EONSMOKE® byEonsmoke LLC; FIN™ by FIN Branding Group, LLC; SMOKE® by Green SmokeInc. USA; GREENARETTE™ by Greenarette LLC; HALLIGAN™ HENDU™ JET™, MAXXQ™PINK™ and PITBULL™ by SMOKE STIK®; HEATBAR™ by Philip MorrisInternational, Inc.; HYDRO IMPERIAL™ and LXE™ from Crown7; LOGIC™ andTHE CUBAN™ by LOGIC Technology; LUCI® by Luciano Smokes Inc.; METRO® byNicotek, LLC; NJOY® and ONEJOY™ by Sottera, Inc.; NO. 7™ by SS ChoiceLLC; PREMIUM ELECTRONIC CIGARETTE™ by PremiumEstore LLC; RAPP E-MYSTICK™by Ruyan America, Inc.; RED DRAGON™ by Red Dragon Products, LLC; RUYAN®by Ruyan Group (Holdings) Ltd.; SF® by Smoker Friendly International,LLC; GREEN SMART SMOKER® by The Smart Smoking Electronic CigaretteCompany Ltd.; SMOKE ASSIST® by Coastline Products LLC; SMOKINGEVERYWHERE® by Smoking Everywhere, Inc.; V2CIGS™ by VMR Products LLC;VAPOR NINE™ by VaporNine LLC; VAPOR4LIFE® by Vapor 4 Life, Inc.; VEPPO™by E-CigaretteDirect, LLC; VUSE® by R. J. Reynolds Vapor Company; MisticMenthol product by Mistic Ecigs; and the Vype product by CN CreativeLtd; IQOS™ by Philip Morris International; and GLO™ by British AmericanTobacco. Yet other electrically powered aerosol delivery devices, and inparticular those devices that have been characterized as so-calledelectronic cigarettes, have been marketed under the tradenames COOLERVISIONS™; DIRECT E-CIG™; DRAGONFLY™; EMIST™; EVERSMOKE™; GAMUCCI®;HYBRID FLAME™; KNIGHT STICKS™; ROYAL BLUES™; SMOKETIP®; and SOUTH BEACHSMOKE™.

Articles that produce the taste and sensation of smoking by electricallyheating tobacco, tobacco derived materials, or other plant derivedmaterials have suffered from inconsistent performance characteristics.For example, some articles have suffered from inconsistent release offlavors or other inhalable materials. Accordingly, it can be desirableto provide a smoking article that can provide the sensations ofcigarette, cigar, or pipe smoking, that does so without combusting thesubstrate material, that does so without the need of a combustion heatsource, and that does so with increased performance characteristics.

BRIEF SUMMARY

In various implementations, the present disclosure provides an aerosoldelivery device. In one implementation, the aerosol delivery device maycomprise an aerosol source member that defines an outer surface and aninterior area and may include a substrate material having an aerosolprecursor composition associated therewith, a control body having ahousing that is configured to receive the aerosol source member, anelectrical energy source coupled with the housing, and a heatingassembly operatively connected to the electrical energy source. Theheating assembly may include a plurality of spikes, and the plurality ofspikes may be configured to articulate between a retracted position, inwhich the plurality of spikes are not in contact with the aerosol sourcemember, and a heating position, in which the plurality of spikes piercesthrough the outer surface of the substrate material and into a portionof the interior area thereof. In some implementations, the outer surfaceof the substrate material may include a plurality of spaced conductivebands. In some implementations, each of the spaced conductive bands maycircumscribe the entire outer surface of the substrate material. In someimplementations, each of the spaced conductive bands may extend around alimited portion of the outer surface of the substrate material and maydefine a first end and a second end. In some implementations, in theheating position, respective spikes of the plurality of heat conductingspikes may contact the first and second ends of the spaced conductivebands. In some implementations, the plurality of spikes may comprise aheating member of the heating assembly.

In some implementations, the plurality of spaced conductive bands maycomprise a heating member of the heating assembly. In someimplementations, the aerosol source member further comprises a secondsubstrate material that defines an outer surface and an interior area,and wherein the second substrate material substantially surrounds thefirst substrate material. In some implementations, the outer surface ofthe first substrate material may include a plurality of spacedconductive bands. In some implementations, each of the spaced conductivebands may circumscribe the entire outer surface of the substratematerial. In some implementations, each of the spaced conductive bandsmay extend around a portion of the outer surface of the substratematerial and may define a first end and a second end. In someimplementations, in the heating position, respective spikes of theplurality of spikes may contact the first and second ends of the spacedconductive bands. In some implementations, the plurality of spikes maycomprise a heating member of the heating assembly. In someimplementations, the plurality of spaced conductive bands may comprise aheating member of the heating assembly. In some implementations, thesubstrate material may comprise at least one of a tobacco material and atobacco-derived material. In some implementations, the substratematerial may comprise a non-tobacco material. In some implementations,the first substrate material may comprise a first composition, thesecond substrate material may comprise a second composition, and thefirst composition may be different than the second composition. In someimplementations, the substrate material may comprise at least one ofshreds of tobacco material, beads of tobacco material, an extrudedstructure of tobacco material, a crimped sheet of tobacco material, andcombinations thereof. In some implementations, the first substratematerial may comprise at least one of shreds of tobacco material, beadsof tobacco material, an extruded structure of tobacco material, acrimped sheet of tobacco material, and combinations thereof. In someimplementations, the second substrate material may comprise at least oneof shreds of tobacco material, beads of tobacco material, an extrudedstructure of tobacco material, a crimped sheet of tobacco material, andcombinations thereof.

These and other features, aspects, and advantages of the disclosure willbe apparent from a reading of the following detailed descriptiontogether with the accompanying drawings, which are briefly describedbelow.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described aspects of the disclosure in the foregoing generalterms, reference will now be made to the accompanying drawings, whichare not necessarily drawn to scale, and wherein:

FIG. 1 illustrates a schematic front view of an aerosol delivery devicecomprising a control body, an aerosol source member, and a heatingassembly, according to an example implementation of the presentdisclosure;

FIG. 2 illustrates a front schematic view of a portion of a heated endof an aerosol source member and a portion of a heating assembly,according to an example implementation of the present disclosure;

FIG. 3 illustrates a perspective schematic view of a portion of a heatedend of an aerosol source member and a portion of a heating assembly,according to an example implementation of the present disclosure;

FIG. 4 illustrates a perspective schematic view of a portion of a heatedend of an aerosol source member, according to an example implementationof the present disclosure;

FIG. 5 illustrates a perspective schematic view of a portion of a heatedend of an aerosol source member and a portion of a heating assembly,according to an example implementation of the present disclosure;

FIG. 6 illustrates a top schematic view of a heated end of an aerosolsource member and a portion of a heating assembly, according to anexample implementation of the present disclosure;

FIG. 7 illustrates a perspective schematic drawing of a portion of aheated end an aerosol source member and a portion of a heating assembly,according to an example implementation of the present disclosure; and

FIG. 8 illustrates a top schematic view of a heated end of an aerosolsource member and a portion of a heating assembly, according to anexample implementation of the present disclosure.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter withreference to example implementations thereof. These exampleimplementations are described so that this disclosure will be thoroughand complete, and will fully convey the scope of the disclosure to thoseskilled in the art. Indeed, the disclosure may be embodied in manydifferent forms and should not be construed as limited to theimplementations set forth herein; rather, these implementations areprovided so that this disclosure will satisfy applicable legalrequirements. As used in the specification and the appended claims, thesingular forms “a,” “an,” “the” and the like include plural referentsunless the context clearly dictates otherwise. Also, while reference maybe made herein to quantitative measures, values, geometric relationshipsor the like, unless otherwise stated, any one or more if not all ofthese may be absolute or approximate to account for acceptablevariations that may occur, such as those due to engineering tolerancesor the like.

As described hereinafter, example implementations of the presentdisclosure relate to aerosol delivery devices for use with aerosolsource members. Aerosol delivery devices according to the presentdisclosure use electrical energy to heat a material (preferably withoutcombusting the material to any significant degree) to form an inhalablesubstance; and components of such systems have the form of articles thatare sufficiently compact to be considered hand-held devices. That is,use of components of preferred aerosol delivery devices does not resultin the production of smoke in the sense that aerosol results principallyfrom by-products of combustion or pyrolysis of tobacco, but rather, useof those preferred systems results in the production of vapors resultingfrom volatilization or vaporization of certain components incorporatedtherein. In some example implementations, components of aerosol deliverydevices may be characterized as electronic cigarettes, and thoseelectronic cigarettes most preferably incorporate tobacco and/orcomponents derived from tobacco, and hence deliver tobacco derivedcomponents in aerosol form.

Aerosol generating components of certain preferred aerosol deliverydevices may provide many of the sensations (e.g., inhalation andexhalation rituals, types of tastes or flavors, organoleptic effects,physical feel, use rituals, visual cues such as those provided byvisible aerosol, and the like) of smoking a cigarette, cigar or pipethat is employed by lighting and burning tobacco (and hence inhalingtobacco smoke), without any substantial degree of combustion of anycomponent thereof. For example, the user of an aerosol delivery devicein accordance with some example implementations of the presentdisclosure can hold and use that component much like a smoker employs atraditional type of smoking article, draw on one end of that piece forinhalation of aerosol produced by that piece, take or draw puffs atselected intervals of time, and the like.

While the systems are generally described herein in terms ofimplementations associated with aerosol delivery devices such asso-called “e-cigarettes” or “tobacco heating products,” it should beunderstood that the mechanisms, components, features, and methods may beembodied in many different forms and associated with a variety ofarticles. For example, the description provided herein may be employedin conjunction with implementations of traditional smoking articles(e.g., cigarettes, cigars, pipes, etc.), heat-not-burn cigarettes, andrelated packaging for any of the products disclosed herein. Accordingly,it should be understood that the description of the mechanisms,components, features, and methods disclosed herein are discussed interms of implementations relating to aerosol delivery devices by way ofexample only, and may be embodied and used in various other products andmethods.

Aerosol delivery devices of the present disclosure may also becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices may be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances may be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances may be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like. The physicalform of the inhalable substance is not necessarily limited by the natureof the inventive devices but rather may depend upon the nature of themedium and the inhalable substance itself as to whether it exists in avapor state or an aerosol state. In some implementations, the terms maybe interchangeable. Thus, for simplicity, the terms as used to describeaspects of the disclosure are understood to be interchangeable unlessstated otherwise.

Aerosol delivery devices of the present disclosure generally include anumber of components provided within an outer body or shell, which maybe referred to as a housing. The overall design of the outer body orshell may vary, and the format or configuration of the outer body thatmay define the overall size and shape of the aerosol delivery device mayvary. Typically, an elongate body resembling the shape of a cigarette orcigar, or a fob-shaped body, may be a formed from a single, unitaryhousing or the housing can be formed of two or more separable bodies.For example, an aerosol delivery device may comprise an elongated shellor body that may be substantially tubular in shape and, as such,resemble the shape of a conventional cigarette or cigar. In anotherexample, an aerosol delivery device may have a box or fob shape. In oneexample, all of the components of the aerosol delivery device arecontained within one housing. Alternatively, an aerosol delivery devicemay comprise two or more housings that are joined and are separable. Forexample, an aerosol delivery device may possess a control bodycomprising a housing containing one or more reusable components (e.g.,an accumulator such as a rechargeable battery and/or rechargeablesupercapacitor, and various electronics for controlling the operation ofthat article), removably coupleable thereto, a disposable portion (e.g.,a disposable flavor-containing aerosol source member). More specificformats, configurations and arrangements of components within the singlehousing type of unit or within a multi-piece separable housing type ofunit will be evident in light of the further disclosure provided herein.Additionally, various aerosol delivery device designs and componentarrangements may be appreciated upon consideration of the commerciallyavailable electronic aerosol delivery devices.

As will be discussed in more detail below, aerosol delivery devices ofthe present disclosure may comprise some combination of a power source(i.e., an electrical energy source), at least one control component(e.g., means for actuating, controlling, regulating and ceasing powerfor heat generation, such as by controlling electrical current flow fromthe electrical energy source to other components of the device—e.g., amicroprocessor, individually or as part of a microcontroller), a heateror heat generation member (e.g., an electrical resistance heatingelement or other component and/or an inductive coil or other associatedcomponents and/or one or more radiant heating elements), and an aerosolsource member that includes a substrate material capable of yielding anaerosol upon application of sufficient heat. In various implementations,the aerosol source member may include a mouth end or tip configured toallow drawing upon the aerosol delivery device for aerosol inhalation(e.g., a defined airflow path through the device such that aerosolgenerated can be withdrawn therefrom upon draw).

Alignment of the components within the aerosol delivery device of thepresent disclosure may vary across various implementations. In someimplementations, substrate material of an aerosol source member may bepositioned proximate a heating member so as to maximize aerosol deliveryto the user. Other configurations, however, are not excluded. Generally,the heating member may be positioned sufficiently near the substratematerial so that heat from the heating member can volatilize thesubstrate material (as well as, in some implementations, one or moreflavourants, medicaments, or the like that may likewise be provided fordelivery to a user) and form an aerosol for delivery to the user. Whenthe heating member heats the substrate material, an aerosol is formed,released, or generated in a physical form suitable for inhalation by aconsumer. It should be noted that the foregoing terms are meant to beinterchangeable such that reference to release, releasing, releases, orreleased includes form or generate, forming or generating, forms orgenerates, and formed or generated. Specifically, an inhalable substanceis released in the form of a vapor or aerosol or mixture thereof,wherein such terms are also interchangeably used herein except whereotherwise specified.

As noted above, the aerosol delivery device of various implementationsmay incorporate a battery and/or other electrical source to providecurrent flow sufficient to provide various functionalities to theaerosol delivery device, such as powering of a heating member, poweringof control systems, powering of indicators, and the like. As will bediscussed in more detail below, the electrical energy source may take onvarious implementations. Preferably, the electrical energy source may beable to deliver sufficient power to rapidly activate the heating memberto provide for aerosol formation and power the aerosol delivery devicethrough use for a desired duration of time. The electrical energy sourceis preferably sized to fit conveniently within the aerosol deliverydevice so that the aerosol delivery device can be easily handled.

In further implementations, the electrical energy source may alsocomprise a capacitor. Capacitors are capable of discharging more quicklythan batteries and can be charged between puffs, allowing the battery todischarge into the capacitor at a lower rate than if it were used topower the heating member directly. For example, a supercapacitor—e.g.,an electric double-layer capacitor (EDLC)—may be used separate from orin combination with a battery. When used alone, the supercapacitor maybe recharged before each use of the device. Thus, the device may alsoinclude a charger component that can be attached to the smoking devicebetween uses to replenish the supercapacitor.

Further components may be utilized in the aerosol delivery device of thepresent disclosure. For example, the aerosol delivery device may includea flow sensor that is sensitive either to pressure changes or air flowchanges as the consumer draws on the device (e.g., a puff-actuatedswitch). Other possible current actuation/deactuation mechanisms mayinclude a temperature actuated on/off switch or a lip pressure actuatedswitch. An example mechanism that can provide such puff-actuationcapability includes a Model 163PC01D36 silicon sensor, manufactured bythe MicroSwitch division of Honeywell, Inc., Freeport, Ill.Representative flow sensors, current regulating components, and othercurrent controlling components including various microcontrollers,sensors, and switches for aerosol delivery devices are described in U.S.Pat. No. 4,735,217 to Gerth et al., U.S. Pat. Nos. 4,922,901, 4,947,874,and 4,947,875, all to Brooks et al., U.S. Pat. No. 5,372,148 toMcCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S.Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No. 8,205,622 to Pan,all of which are incorporated herein by reference in their entireties.Reference also is made to the control schemes described in U.S. Pat. No.9,423,152 to Ampolini et al., which is incorporated herein by referencein its entirety.

In another example, a personal vaporizer unit may comprise a firstconductive surface configured to contact a first body part of a userholding the personal vaporizer unit, and a second conductive surface,conductively isolated from the first conductive surface, configured tocontact a second body part of the user. As such, when the personalvaporizer unit detects a change in conductivity between the firstconductive surface and the second conductive surface, a vaporizer isactivated to vaporize a substance so that the vapors may be inhaled bythe user holding unit. The first body part and the second body part maybe a lip or parts of a hand(s). The two conductive surfaces may also beused to charge a battery contained in the personal vaporizer unit. Thetwo conductive surfaces may also form, or be part of, a connector thatmay be used to output data stored in a memory. Reference is made to U.S.Pat. No. 9,861,773 to Terry et al., which is incorporated herein byreference in its entirety.

In addition, U.S. Pat. No. 5,154,192 to Sprinkel et al. disclosesindicators for smoking articles; U.S. Pat. No. 5,261,424 to Sprinkel,Jr. discloses piezoelectric sensors that can be associated with themouth-end of a device to detect user lip activity associated with takinga draw and then trigger heating of a heating device; U.S. Pat. No.5,372,148 to McCafferty et al. discloses a puff sensor for controllingenergy flow into a heating load array in response to pressure dropthrough a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. disclosesreceptacles in a smoking device that include an identifier that detectsa non-uniformity in infrared transmissivity of an inserted component anda controller that executes a detection routine as the component isinserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer etal. describes a defined executable power cycle with multipledifferential phases; U.S. Pat. No. 5,934,289 to Watkins et al. disclosesphotonic-optronic components; U.S. Pat. No. 5,954,979 to Counts et al.discloses means for altering draw resistance through a smoking device;U.S. Pat. No. 6,803,545 to Blake et al. discloses specific batteryconfigurations for use in smoking devices; U.S. Pat. No. 7,293,565 toGriffen et al. discloses various charging systems for use with smokingdevices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses computerinterfacing means for smoking devices to facilitate charging and allowcomputer control of the device; U.S. Pat. No. 8,689,804 to Fernando etal. discloses identification systems for smoking devices; and PCT Pat.App. Pub. No. WO 2010/003480 by Flick discloses a fluid flow sensingsystem indicative of a puff in an aerosol generating system; all of theforegoing disclosures being incorporated herein by reference in theirentireties.

Further examples of components related to electronic aerosol deliveryarticles and disclosing materials or components that may be used in thepresent device include U.S. Pat. No. 4,735,217 to Gerth et al.; U.S.Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977 to Higginset al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 toFelter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No.7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No.7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat. Nos.8,156,944 and 8,375,957 to Hon; U.S. Pat. No. 8,794,231 to Thorens etal.; U.S. Pat. No. 8,851,083 to Oglesby et al.; U.S. Pat. Nos. 8,915,254and 8,925,555 to Monsees et al.; U.S. Pat. No. 9,220,302 to DePiano etal.; U.S. Pat. App. Pub. Nos. 2006/0196518 and 2009/0188490 to Hon; U.S.Pat. App. Pub. No. 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub.No. 2010/0307518 to Wang; PCT Pat. App. Pub. No. WO 2010/091593 to Hon;and PCT Pat. App. Pub. No. WO 2013/089551 to Foo, each of which isincorporated herein by reference in its entirety. Further, U.S. Pat.App. Pub. No. 2017/0099877 to Worm et al., filed Oct. 13, 2015,discloses capsules that may be included in aerosol delivery devices andfob-shape configurations for aerosol delivery devices, and isincorporated herein by reference in its entirety. A variety of thematerials disclosed by the foregoing documents may be incorporated intothe present devices in various implementations, and all of the foregoingdisclosures are incorporated herein by reference in their entireties.

More specific formats, configurations and arrangements of varioussubstrate materials, aerosol source members, and components withinaerosol delivery devices of the present disclosure will be evident inlight of the further disclosure provided hereinafter. Additionally, theselection of various aerosol delivery device components may beappreciated upon consideration of the commercially available electronicaerosol delivery devices. Further, the arrangement of the componentswithin the aerosol delivery device may also be appreciated uponconsideration of the commercially available electronic aerosol deliverydevices.

A front schematic illustration of an example implementation of anaerosol delivery device 100 in accordance with the present disclosure isshown in FIG. 1 . In general, the aerosol delivery device 100 of thedepicted implementation includes a control body 102 that includes ahousing 104 configured to receive an aerosol source member 200. In thedepicted implementation, the control body 102 may also include a controlcomponent 106 (e.g., a microprocessor, individually or as part of amicrocontroller, a printed circuit board (PCB) that includes amicroprocessor and/or microcontroller, etc.) and an electrical energysource 108 (e.g., a battery, which may be rechargeable, and/or arechargeable supercapacitor). In various implementations, one or both ofthe control component 106 and the electrical energy source 108 may becoupled with the housing 104. For the sake of the current application,the phrase “coupled with” when used with respect to one componentrelative to another may encompass implementations in which one componentis located within another component and/or implementations wherein onecomponent is separate but otherwise operatively connected to anothercomponent. For example, in the depicted implementation, both the controlcomponent 106 and the electrical energy source 108 are located withinthe housing; however, in other implementations one or both of thecontrol component 106 and the electrical energy source 108 may beseparate components. Further information regarding the control component106 and the electrical energy source 108 is provided below. In someimplementations, the housing 104 may also include a pushbuttonconfigured to activate certain operations of the device 100, such as,for example, turning on the device and initiating heating of a heatingmember. In various implementations, the aerosol source member 200 maycomprise a heated end 202, which is configured to be inserted into thecontrol body 102, and a mouth end 204, upon which a user draws to createthe aerosol. It should be noted that while the aerosol delivery deviceof FIG. 1 is shown as having a substantially rectangular or fob-shapedcontrol body 102 for ease of illustration, in other implementations thecontrol body 102 may have any other shape including an elongated shellor body that may be substantially tubular in shape and, as such,resemble the shape of a conventional cigarette or cigar, and thus thecomponents described below may be sized and configured to fit inside anelongated body.

In specific implementations, one or both of the control body 102 and theaerosol source member 200 may be referred to as being disposable or asbeing reusable. For example, the control body 102 may have a replaceablebattery or a rechargeable battery, solid-state battery, thin-filmsolid-state battery, rechargeable supercapacitor or the like, and thusmay be combined with any type of recharging technology, includingconnection to a wall charger, connection to a car charger (i.e.,cigarette lighter receptacle), and connection to a computer, such asthrough a universal serial bus (USB) cable or connector (e.g., USB 2.0,3.0, 3.1, USB Type-C), connection to a photovoltaic cell (sometimesreferred to as a solar cell) or solar panel of solar cells, a wirelesscharger, such as a charger that uses inductive wireless charging(including for example, wireless charging according to the Qi wirelesscharging standard from the Wireless Power Consortium (WPC)), or awireless radio frequency (RF) based charger. An example of an inductivewireless charging system is described in U.S. Pat. App. Pub. No.2017/0112196 to Sur et al., which is incorporated herein by reference inits entirety. Further, in some implementations, the aerosol sourcemember 200 may comprise a single-use device. A single use component foruse with a control body is disclosed in U.S. Pat. No. 8,910,639 to Changet al., which is incorporated herein by reference in its entirety.

As noted above, the control body 102 may further include a controlcomponent 106. For example, the control component 106 may comprise acontrol circuit (which may be connected to further components, asfurther described herein) that may be connected by electricallyconductive wires to the electrical energy source 108. In variousimplementations, the control component 106 may control when and how theheating member receives electrical energy to heat the inhalablesubstance medium for release of the inhalable substance for inhalationby a consumer. Such control can relate to actuation of pressuresensitive switches or the like, which are described in greater detailhereinafter. It should be noted that the terms “connected” or “coupled”should not be read as necessitating direct connection without anintervening component. Rather, these terms may encompass directconnection and/or connection via one or more intervening components. Assuch, in various implementations these terms may be understood to meanoperatively connected to or operatively coupled with.

In various implementations, the control component 106 may also beconfigured to closely control the amount of heat provided to thesubstrate material. While the heat needed to volatilize theaerosol-forming substance in a sufficient volume to provide a desireddosing of the inhalable substance for a single puff can vary for eachparticular substance used, it can be particularly useful for the heatingmember to heat to a temperature of at least 120° C., at least 130° C.,or at least 140° C. In some implementations, in order to volatilize anappropriate amount of the aerosol-forming substance and thus provide adesired dosing of the inhalable substance, the heating temperature maybe at least 150° C., at least 200° C., at least 300° C., or at least350° C. It can be particularly desirable, however, to avoid heating totemperatures substantially in excess of about 550° C. in order to avoiddegradation and/or excessive, premature volatilization of theaerosol-forming substance. Heating specifically should be at asufficiently low temperature and sufficiently short time so as to avoidsignificant combustion (preferably any combustion) of the inhalablesubstance medium. The present disclosure may particularly provide thecomponents of the present article in combinations and modes of use thatwill yield the inhalable substance in desired amounts at relatively lowtemperatures. As such, yielding can refer to one or both of generationof the aerosol within the article and delivery out of the article to aconsumer. In specific implementations, the heating temperature may beabout 120° C. to about 300° C., about 130° C. to about 290° C., about140° C. to about 280° C., about 150° C. to about 250° C., or about 160°C. to about 200° C. The duration of heating can be controlled by anumber of factors, as discussed in greater detail hereinbelow. Heatingtemperature and duration may depend upon the desired volume of aerosoland ambient air that is desired to be drawn through the aerosol sourcemember, as further described herein. The duration, however, may bevaried depending upon the heating rate of the heating member, as thearticle may be configured such that the heating member is energized onlyuntil a desired temperature is reached. Alternatively, duration ofheating may be coupled to the duration of a puff on the article by aconsumer. Generally, the temperature and time of heating will becontrolled by one or more components contained in the control body, asnoted above.

The amount of inhalable material released by the aerosol source membercan vary based upon the nature of the inhalable material. Preferably,the aerosol source member is configured with a sufficient amount of theinhalable material, with a sufficient amount of any aerosol-former, andto function at a sufficient temperature for a sufficient time to releasea desired amount over a course of use. The amount may be provided in asingle inhalation from the aerosol source member or may be divided so asto be provided through a number of puffs from the article over arelatively short length of time (e.g., less than 30 minutes, less than20 minutes, less than 15 minutes, less than 10 minutes, or less than 5minutes). For example, the device may provide nicotine in an amount ofabout 0.05 mg to about 1.0 mg, about 0.08 mg to about 0.5 mg, about 0.1mg to about 0.3 mg, or about 0.15 mg to about 0.25 mg per puff on theaerosol source member. In other implementations, a desired amount may becharacterized in relation to the amount of wet total particulate matterdelivered based on puff duration and volume. For example, the aerosolsource member may deliver at least 1.0 mg of wet total particulatematter on each puff, for a defined number of puffs (as otherwisedescribed herein), when smoked under standard FTC smoking conditions of2 second, 35 ml puffs. Such testing may be carried out using anystandard smoking machine. In other implementations, the amount of totalparticulate matter (TPM) yielded under the same conditions on each puffmay be at least 1.5 mg, at least 1.7 mg, at least 2.0 mg, at least 2.5mg, at least 3.0 mg, about 1.0 mg to about 5.0 mg, about 1.5 mg to about4.0 mg, about 2.0 mg to about 4.0 mg, or about 2.0 mg to about 3.0 mg.

As noted, the aerosol delivery device 100 of some implementations mayinclude a pushbutton, which may be linked to the control component formanual control of the heating assembly 110. For example, in someimplementations the consumer may use the pushbutton to energize theheating assembly 110. Similar functionality tied to the pushbutton maybe achieved by other mechanical means or non-mechanical means (e.g.,magnetic or electromagnetic). Thusly, activation of the heating assembly110 may be controlled by a single pushbutton. Alternatively, multiplepushbuttons may be provided to control various actions separately. Oneor more pushbuttons present may be substantially flush with the casingof the control body 102.

Instead of (or in addition to) any pushbuttons, the aerosol deliverydevice 100 of the present disclosure may include components thatenergize the heating assembly 110 in response to the consumer's drawingon the article (i.e., puff-actuated heating). For example, the devicemay include a switch or flow sensor (not shown) in the control body 102that is sensitive either to pressure changes or air flow changes as theconsumer draws on the article (i.e., a puff-actuated switch). Othersuitable current actuation/deactuation mechanisms may include atemperature actuated on/off switch or a lip pressure actuated switch. Anexemplary mechanism that can provide such puff-actuation capabilityincludes a Model 163PC01D36 silicon sensor, manufactured by theMicroSwitch division of Honeywell, Inc., Freeport, Ill. With suchsensor, the heating member may be activated rapidly by a change inpressure when the consumer draws on the device. In addition, flowsensing devices, such as those using hot-wire anemometry principles, maybe used to cause the energizing of the heating assembly sufficientlyrapidly after sensing a change in air flow. A further puff actuatedswitch that may be used is a pressure differential switch, such as ModelNo. MPL-502-V, range A, from Micro Pneumatic Logic, Inc., Ft.Lauderdale, Fla. Another suitable puff actuated mechanism is a sensitivepressure transducer (e.g., equipped with an amplifier or gain stage)which is in turn coupled with a comparator for detecting a predeterminedthreshold pressure. Yet another suitable puff actuated mechanism is avane which is deflected by airflow, the motion of which vane is detectedby a movement sensing means. Yet another suitable actuation mechanism isa piezoelectric switch. Also useful is a suitably connected HoneywellMicroSwitch Microbridge Airflow Sensor, Part No. AWM 2100V fromMicroSwitch Division of Honeywell, Inc., Freeport, Ill. Further examplesof demand-operated electrical switches that may be employed in a heatingcircuit according to the present disclosure are described in U.S. Pat.No. 4,735,217 to Gerth et al., which is incorporated herein by referencein its entirety. Other suitable differential switches, analog pressuresensors, flow rate sensors, or the like, will be apparent to the skilledartisan with the knowledge of the present disclosure. In someimplementations, a pressure-sensing tube or other passage providingfluid connection between the puff actuated switch and aerosol sourcemember 200 may be included in the control body 102 so that pressurechanges during draw are readily identified by the switch. Otherexemplary puff actuation devices that may be useful according to thepresent disclosure are disclosed in U.S. Pat. Nos. 4,922,901, 4,947,874,and 4,947,874, all to Brooks et al., U.S. Pat. No. 5,372,148 toMcCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., andU.S. Pat. No. 7,040,314 to Nguyen et al., all of which are incorporatedherein by reference in their entireties.

When the consumer draws on the mouth end of the device 100, the currentactuation means may permit unrestricted or uninterrupted flow of currentthrough the heating assembly generate heat rapidly. Because of the rapidheating, it can be useful to include current regulating components to(i) regulate current flow through the heating member to control heatingof the resistance element and the temperature experienced thereby, and(ii) prevent overheating and degradation of the substrate material 210.In some implementations, the current regulating circuit may betime-based. Specifically, such a circuit may include a means forpermitting uninterrupted current flow through the heating member for aninitial time period during draw, and a timer means for subsequentlyregulating current flow until draw is completed. For example, thesubsequent regulation can include the rapid on-off switching of currentflow (e.g., on the order of about every 1 to 50 milliseconds) tomaintain the heating member within the desired temperature range.Further, regulation may comprise simply allowing uninterrupted currentflow until the desired temperature is achieved then turning off thecurrent flow completely. The heating member may be reactivated by theconsumer initiating another puff on the article (or manually actuatingthe pushbutton, depending upon the specific switch implementationemployed for activating the heater). Alternatively, the subsequentregulation can involve the modulation of current flow through theheating member to maintain the heating member within a desiredtemperature range. In some implementations, so as to release the desireddosing of the inhalable substance, the heating member may be energizedfor a duration of about 0.2 second to about 5.0 seconds, about 0.3second to about 4.0 seconds, about 0.4 second to about 3.0 seconds,about 0.5 second to about 2.0 seconds, or about 0.6 second to about 1.5seconds. One exemplary time-based current regulating circuit can includea transistor, a timer, a comparator, and a capacitor. Suitabletransistors, timers, comparators, and capacitors are commerciallyavailable and will be apparent to the skilled artisan. Exemplary timersare those available from NEC Electronics as C-1555C and from GeneralElectric Intersil, Inc. as ICM7555, as well as various other sizes andconfigurations of so-called “555 Timers”. An exemplary comparator isavailable from National Semiconductor as LM311. Further description ofsuch time-based current regulating circuits is provided in U.S. Pat. No.4,947,874 to Brooks et al., which is incorporated herein by reference inits entirety.

In light of the foregoing, it can be seen that a variety of mechanismscan be employed to facilitate actuation/deactuation of current to theheating member. For example, the device may include a timer forregulating current flow in the article (such as during draw by aconsumer). The device may further include a timer responsive switch thatenables and disables current flow to the heating member. Current flowregulation also can comprise use of a capacitor and components forcharging and discharging the capacitor at a defined rate (e.g., a ratethat approximates a rate at which the heating member heats and cools).Current flow specifically may be regulated such that there isuninterrupted current flow through the heating member for an initialtime period during draw, but the current flow may be turned off orcycled alternately off and on after the initial time period until drawis completed. Such cycling may be controlled by a timer, as discussedabove, which can generate a preset switching cycle. In specificimplementations, the timer may generate a periodic digital wave form.The flow during the initial time period further may be regulated by useof a comparator that compares a first voltage at a first input to athreshold voltage at a threshold input and generates an output signalwhen the first voltage is equal to the threshold voltage, which enablesthe timer. Such implementations further can include components forgenerating the threshold voltage at the threshold input and componentsfor generating the threshold voltage at the first input upon passage ofthe initial time period.

As noted above, the electrical energy source 108 used to provide powerto the various electrical components of the device 100 may take onvarious implementations. Preferably, the electrical energy source isable to deliver sufficient energy to rapidly heat the heating assemblyin the manner described above and power the device through use withmultiple aerosol source members 200 while still fitting conveniently inthe device 100. Examples of useful electrical energy sources includelithium-ion batteries that are preferably rechargeable (e.g., arechargeable lithium-manganese dioxide battery). In particular, lithiumpolymer batteries can be used as such batteries can provide increasedsafety. Other types of batteries—e.g., nickel-cadmium cells—may also beused. Additionally, a preferred electrical energy source is of asufficiently light weight to not detract from a desirable smokingexperience. Some examples of possible electrical energy sources aredescribed in U.S. Pat. No. 9,484,155 to Peckerar et al., and U.S. Pat.App. Pub. No. 2017/0112191 to Sur et al., filed Oct. 21, 2015, thedisclosures of which are incorporated herein by reference in theirrespective entireties.

One example of an electrical energy source is a TKI-1550 rechargeablelithium-ion battery produced by Tadiran Batteries GmbH of Germany. Inanother implementation, a useful electrical energy source may be aN50-AAA CADNICA nickel-cadmium cell produced by Sanyo Electric Company,Ltd., of Japan. In other implementations, a plurality of such batteries,for example providing 1.2-volts each, may be connected in series. Otherelectrical energy sources, such as rechargeable lithium-manganesedioxide batteries, may also be used. Any of these batteries orcombinations thereof may be used in the electrical energy source, butrechargeable batteries are preferred because of cost and disposalconsiderations associated with disposable batteries. In implementationswhere rechargeable batteries are used, the aerosol delivery device 100may further include charging contacts for interaction with correspondingcontacts in a conventional recharging unit (not shown) deriving powerfrom a standard 120-volt AC wall outlet, or other sources such as anautomobile electrical system or a separate portable power supply. Infurther implementations, the electrical energy source may also comprisea capacitor. Capacitors are capable of discharging more quickly thanbatteries and can be charged between puffs, allowing the battery todischarge into the capacitor at a lower rate than if it were used topower the heating member directly. For example, a supercapacitor—i.e.,an electric double-layer capacitor (EDLC)—may be used separate from orin combination with a battery. When used alone, the supercapacitor maybe recharged before each use of the device 100. Thus, the presentdisclosure also may include a charger component that can be attached tothe device between uses to replenish the supercapacitor. Thin filmbatteries may be used in certain implementations of the presentdisclosure.

As noted above, in various implementations, the aerosol delivery device100 may comprise one or more indicators (not shown). In variousimplementations, one or more indicators may be located at any locationon the control body 102. In some implementations, the indicators may belights (e.g., light emitting diodes) that may provide indication ofmultiple aspects of use of the device. For example, a series of lightsmay correspond to the number of puffs for a given aerosol source member.Specifically, the lights may successively become lit with each puff suchthat when all lights are lit, the consumer is informed that the aerosolsource member is spent. Alternatively, all lights may be lit upon theaerosol source member being inserted into the housing, and a light mayturn off with each puff, such that when all lights are off, the consumeris informed that the aerosol source member is spent. In still otherimplementations, only a single indicator may be present, and lightingthereof may indicate that current was flowing to the heating member andthe device is actively heating. This may ensure that a consumer does notunknowingly leave the device unattended in an actively heating mode. Inalternative implementations, one or more of the indicators may be acomponent of the aerosol source member. Although the indicators aredescribed above in relation to visual indicators in an on/off method,other indices of operation also are encompassed. For example, visualindicators also may include changes in light color or intensity to showprogression of the smoking experience. Tactile indicators and audibleindicators similarly are encompassed by the present disclosure.Moreover, combinations of such indicators also may be used in a singledevice.

In various implementations, the housing 104 may be formed of anymaterial suitable for forming and maintaining an appropriateconformation, such as a tubular or rectangular shape, and for retainingtherein an aerosol source member. In some implementations, the housingmay be formed of a single wall, or multiple walls, and from a materialor multiple materials (natural or synthetic) that are heat resistant soas to retain its structural integrity—e.g., does not degrade—at least ata temperature that is the heating temperature provided by the electricalheating member, as further discussed herein. In some implementations, aheat resistant polymer may be used. In other implementations, ceramicmaterials may be used. In further implementations, an insulatingmaterial may be used so as not to unnecessarily move heat away from theaerosol source member. The housing, when formed of a single layer, mayhave a thickness that preferably is about 0.2 mm to about 5.0 mm, about0.5 mm to about 4.0 mm, about 0.5 mm to about 3.0 mm, or about 1.0 mm toabout 3.0 mm. Further example types of components and materials that maybe used to provide the functions described above or be used asalternatives to the materials and components noted above can be those ofthe types set forth in U.S. Pat. App. Pub. Nos. 2010/00186757 to Crookset al.; 2010/00186757 to Crooks et al.; and 2011/0041861 to Sebastian etal.; the disclosures of the documents being incorporated herein byreference in their entireties.

Referring to FIGS. 1 and 2 , the aerosol source member 200 defines anouter surface 206 and an interior area 208. In the depictedimplementation, a substrate material 210 is located in the interior area208 of the heated end 202 of the aerosol source member 200. In someimplementations, however, substrate material may be located in both theheated end 202 and the mouth end 204 of the aerosol source member 200.In the depicted implementation, the substrate material 210 has a singlesegment, although in other implementations the substrate material 210may include additional segments, which may have different compositions.For example, the heated end 202 of some implementations of the aerosolsource member 200 may further comprise a second substrate materialsegment (not shown). In various implementations, one or more of thesubstrate materials may include a tobacco or tobacco related material,with an aerosol precursor composition associated therewith. In otherimplementations, non-tobacco materials may be used, such as a cellulosepulp material. In other implementations, the non-tobacco substratematerial may not be a plant-derived material. Other possiblecompositions, components, and/or additives for use in a substratematerial (and/or substrate materials) are described in more detailbelow. It should be noted that the subsequent discussion should beapplicable to any substrate material or substrate material segmentusable in the aerosol delivery devices described herein.

In various implementations, the aerosol source member 200, or a portionthereof, may be wrapped in an exterior overwrap material. In variousimplementations, the mouth end 204 of the aerosol source member 200 mayinclude a filter, which may, for example, be made of a cellulose acetateor polypropylene material. The filter may additionally or alternativelycontain strands of tobacco containing material, such as described inU.S. Pat. No. 5,025,814 to Raker et al., which is incorporated herein byreference in its entirety. In various implementations, the filter mayincrease the structural integrity of the mouth end of the aerosol sourcemember, and/or provide filtering capacity, if desired, and/or provideresistance to draw. The exterior overwrap material may comprise amaterial that resists transfer of heat, which may include a paper orother fibrous material, such as a cellulose material. The exterioroverwrap material may also include at least one filler material imbeddedor dispersed within the fibrous material. In various implementations,the filler material may have the form of water insoluble particles.Additionally, the filler material may incorporate inorganic components.In various implementations, the exterior overwrap may be formed ofmultiple layers, such as an underlying, bulk layer and an overlyinglayer, such as a typical wrapping paper in a cigarette. Such materialsmay include, for example, lightweight “rag fibers” such as flax, hemp,sisal, rice straw, and/or esparto. The exterior overwrap may alsoinclude a material typically used in a filter element of a conventionalcigarette, such as cellulose acetate. Further, an excess length of theexterior overwrap at the mouth end 204 of the aerosol source member mayfunction to simply separate the substrate material from the mouth of aconsumer or to provide space for positioning of a filter material, asdescribed below, or to affect draw on the article or to affect flowcharacteristics of the vapor or aerosol leaving the device during draw.Further discussions relating to the configurations for exterior overwrapmaterials that may be used with the present disclosure may be found inU.S. Pat. No. 9,078,473 to Worm et al., which is incorporated herein byreference in its entirety.

In general, the shape and dimensions of the aerosol source member of thevarious implementations described herein will depend on the size of thehousing, the physics of heat and mass transfer for the geometric design,and/or the expected number of puffs of the aerosol source member.Although a variety of different shapes (e.g., cylindrical, cuboidal,spherical, etc.) and dimensions are possible, in some implementations,an aerosol source member having a cylindrical shape may have an overalldiameter of approximately 5.4 mm and a length of approximately 83 mm. Inother implementations, the aerosol source member may have an overalldiameter of approximately 7-8 mm (such as, for example, approximately7.8 mm) or larger. In other implementations, an aerosol source memberhaving a cuboidal shape may have dimensions of approximately 70 mm×20mm×6 mm. In any of these examples, the dimensions may vary greatly, suchas, for example, ±50% variation in any dimension.

In various implementations, heating of the substrate material 210results in aerosolization of the aerosol precursor compositionassociated with the substrate material 210. In various implementations,the mouth end 204 of the aerosol source member 200 is configured toreceive the generated aerosol therethrough in response to a draw appliedto the mouth end 204 by a user. As noted, the mouth end 204 of theaerosol source member 200 of some implementations may include a filterconfigured to receive the aerosol therethrough in response to the drawapplied to the mouth end 204 of the aerosol source member. Preferably,the elements of the substrate material 210 do not experience thermaldecomposition (e.g., charring, scorching, or burning) to any significantdegree, and the aerosolized components are entrained in the air that isdrawn through the aerosol delivery device 100, including a filter (ifpresent), and into the mouth of the user.

In one implementation, the substrate material may comprise a blend offlavorful and aromatic tobaccos in cut filler form. In anotherimplementation, the substrate material may comprise a reconstitutedtobacco material, such as described in U.S. Pat. No. 4,807,809 to Pryoret al.; U.S. Pat. No. 4,889,143 to Pryor et al. and U.S. Pat. No.5,025,814 to Raker, the disclosures of which are incorporated herein byreference in their entirety. Additionally, a reconstituted tobaccomaterial may include a reconstituted tobacco paper for the type ofcigarettes described in Chemical and Biological Studies on New CigarettePrototypes that Heat Instead of Burn Tobacco, R. J. Reynolds TobaccoCompany Monograph (1988), the contents of which are incorporated hereinby reference in its entirety. For example, a reconstituted tobaccomaterial may include a sheet-like material containing tobacco and/ortobacco-related materials. As such, in some implementations, thesubstrate material may be formed from a wound roll of a reconstitutedtobacco material. In another implementation, the substrate material maybe formed from shreds, strips, and/or the like of a reconstitutedtobacco material. In another implementation, the tobacco sheet maycomprise a crimped sheet of reconstituted tobacco material. In someimplementations, the substrate material may comprise overlapping layers(e.g., a gathered web), which may, or may not, include heat conductingconstituents. Examples of substrate materials that include a series ofoverlapping layers (e.g., gathered webs) of an initial substrate sheetformed by the fibrous filler material, aerosol forming material, andplurality of heat conducting constituents are described in U.S. patentapplication Ser. No. 15/905,320, filed on Feb. 26, 2018, and titled HeatConducting Substrate For Electrically Heated Aerosol Delivery Device,which is incorporated herein by reference in its entirety.

In some implementations, the substrate material may include a pluralityof microcapsules, beads, granules, and/or the like having atobacco-related material. For example, a representative microcapsule maybe generally spherical in shape, and may have an outer cover or shellthat contains a liquid center region of a tobacco-derived extract and/orthe like. In some implementations, one or more of the substratematerials may include a plurality of microcapsules each formed into ahollow cylindrical shape. In some implementations, one or more of thesubstrate materials may include a binder material configured to maintainthe structural shape and/or integrity of the plurality of microcapsulesformed into the hollow cylindrical shape.

Tobacco employed in one or more of the substrate materials may include,or may be derived from, tobaccos such as flue-cured tobacco, burleytobacco, Oriental tobacco, Maryland tobacco, dark tobacco, dark-firedtobacco and Rustica tobacco, as well as other rare or specialtytobaccos, or blends thereof. Various representative tobacco types,processed types of tobaccos, and types of tobacco blends are set forthin U.S. Pat. No. 4,836,224 to Lawson et al.; U.S. Pat. No. 4,924,888 toPerfetti et al.; U.S. Pat. No. 5,056,537 to Brown et al.; U.S. Pat. No.5,159,942 to Brinkley et al.; U.S. Pat. No. 5,220,930 to Gentry; U.S.Pat. No. 5,360,023 to Blakley et al.; U.S. Pat. No. 6,701,936 to Shaferet al.; U.S. Pat. No. 6,730,832 to Dominguez et al.; U.S. Pat. No.7,011,096 to Li et al.; U.S. Pat. No. 7,017,585 to Li et al.; U.S. Pat.No. 7,025,066 to Lawson et al.; U.S. Pat. App. Pub. No. 2004/0255965 toPerfetti et al.; PCT Pub. No. WO 02/37990 to Bereman; and Bombick etal., Fund. Appl. Toxicol., 39, p. 11-17 (1997); the disclosures of whichare incorporated herein by reference in their entireties.

In still other implementations of the present disclosure, the substratematerial may include an extruded structure that includes, or isessentially comprised of a tobacco, a tobacco related material,glycerin, water, and/or a binder material, although certain formulationsmay exclude the binder material. In various implementations, suitablebinder materials may include alginates, such as ammonium alginate,propylene glycol alginate, potassium alginate, and sodium alginate.Alginates, and particularly high viscosity alginates, may be employed inconjunction with controlled levels of free calcium ions. Other suitablebinder materials include hydroxypropylcellulose such as Klucel H fromAqualon Co.; hydroxypropylmethylcellulose such as Methocel K4MS from TheDow Chemical Co.; hydroxyethylcellulose such as Natrosol 250 MRCS fromAqualon Co.; microcrystalline cellulose such as Avicel from FMC;methylcellulose such as Methocel A4M from The Dow Chemical Co.; andsodium carboxymethyl cellulose such as CMC 7HF and CMC 7H4F fromHercules Inc. Still other possible binder materials include starches(e.g., corn starch), guar gum, carrageenan, locust bean gum, pectins andxanthan gum. In some implementations, combinations or blends of two ormore binder materials may be employed. Other examples of bindermaterials are described, for example, in U.S. Pat. No. 5,101,839 toJakob et al.; and U.S. Pat. No. 4,924,887 to Raker et al., each of whichis incorporated herein by reference in its entirety. In someimplementations, the aerosol forming material may be provided as aportion of the binder material (e.g., propylene glycol alginate). Inaddition, in some implementations, the binder material may comprisemicrocellulose or nanocellulose derived from a tobacco or other biomass.

In some implementations, the substrate material may include an extrudedmaterial, as described in U.S. Pat. App. Pub. No. 2012/0042885 to Stoneet al., which is incorporated herein by reference in its entirety. Inyet another implementation, the substrate material may include anextruded structure and/or substrate formed from marumarized and/ornon-marumarized tobacco. Marumarized tobacco is known, for example, fromU.S. Pat. No. 5,105,831 to Banerjee, et al., which is incorporated byreference herein in its entirety. Marumarized tobacco includes about 20to about 50 percent (by weight) tobacco blend in powder form, withglycerol (at about 20 to about 30 percent weight), calcium carbonate(generally at about 10 to about 60 percent by weight, often at about 40to about 60 percent by weight), along with binder agents, as describedherein, and/or flavoring agents. In various implementations, theextruded material may have one or more longitudinal openings.

In various implementations, the substrate material may take on a varietyof conformations based upon the various amounts of materials utilizedtherein. For example, a sample substrate material may comprise up toapproximately 98% by weight, up to approximately 95% by weight, or up toapproximately 90% by weight of a tobacco and/or tobacco relatedmaterial. A sample substrate material may also comprise up toapproximately 25% by weight, approximately 20% by weight, orapproximately 15% by weight water—particularly approximately 2% toapproximately 25%, approximately 5% to approximately 20%, orapproximately 7% to approximately 15% by weight water. Flavors and thelike (which include, for example, medicaments, such as nicotine) maycomprise up to approximately 10%, up to about 8%, or up to about 5% byweight of the aerosol delivery component.

Additionally or alternatively, the substrate material may include anextruded structure and/or a substrate that includes or essentially iscomprised of tobacco, glycerin, water, and/or binder material, and isfurther configured to substantially maintain its structure throughoutthe aerosol-generating process. That is, the substrate material may beconfigured to substantially maintain its shape (e.g., the substratematerial does not continually deform under an applied shear stress)throughout the aerosol-generating process. Although such an examplesubstrate material may include liquids and/or some moisture content, thesubstrate may remain substantially solid throughout theaerosol-generating process and may substantially maintain structuralintegrity throughout the aerosol-generating process. Example tobaccoand/or tobacco related materials suitable for a substantially solidsubstrate material are described in U.S. Pat. App. Pub. No. 2015/0157052to Ademe et al.; U.S. Pat. App. Pub. No. 2015/0335070 to Sears et al.;U.S. Pat. No. 6,204,287 to White; and U.S. Pat. No. 5,060,676 to Hearnet al., which are incorporated herein by reference in their entirety.

In some implementations, the amount of substrate material that is usedwithin the aerosol delivery device may be such that the article exhibitsacceptable sensory and organoleptic properties, and desirableperformance characteristics. For example, in some implementations theaerosol precursor composition such as, for example, glycerin and/orpropylene glycol, may be employed within the substrate material in orderto provide for the generation of a visible mainstream aerosol that inmany regards resembles the appearance of tobacco smoke.

Representative types of further aerosol precursor compositions are setforth in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al.; U.S. Pat.No. 5,101,839 to Jakob et al.; PCT WO 98/57556 to Biggs et al.; andChemical and Biological Studies on New Cigarette Prototypes that HeatInstead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph(1988); the disclosures of which are incorporated herein by reference.In some aspects, a substrate material may produce a visible aerosol uponthe application of sufficient heat thereto (and cooling with air, ifnecessary), and the substrate material may produce an aerosol that is“smoke-like.” In other aspects, the substrate material may produce anaerosol that is substantially non-visible but is recognized as presentby other characteristics, such as flavor or texture. Thus, the nature ofthe produced aerosol may be variable depending upon the specificcomponents of the aerosol delivery component. The substrate material maybe chemically simple relative to the chemical nature of the smokeproduced by burning tobacco.

According to another implementation, an aerosol delivery deviceaccording to the present disclosure may include a substrate materialcomprising a porous, inert material such as, for example, a ceramicmaterial. For example, in some implementations ceramics of variousshapes and geometries (e.g., beads, rods, tubes, etc.) may be used,which have various pore morphology. In addition, in some implementationsnon-tobacco materials, such as e-liquids, may be loaded into theceramics. In another implementation, the substrate material may includea porous, inert material that does not substantially react, chemicallyand/or physically, with a tobacco-related material such as, for example,a tobacco-derived extract. In addition, an extruded tobacco, such asthose described above, may be porous. For example, in someimplementations an extruded tobacco material may have an inert gas, suchas, for example, nitrogen, that acts as a blowing agent during theextrusion process.

As noted above, in various implementations one or more of the substratematerials may include a tobacco, a tobacco component, and/or atobacco-derived material that has been treated, manufactured, produced,and/or processed to incorporate an aerosol precursor composition (e.g.,humectants such as, for example, propylene glycol, glycerin, and/or thelike) and/or at least one flavoring agent, as well as a flame/burnretardant (e.g., diammonium phosphate and/or another salt) configured tohelp prevent ignition, pyrolysis, combustion, and/or scorching of thesubstrate material by the heat source. Various manners and methods forincorporating tobacco into smoking articles, and particularly smokingarticles that are designed so as to not purposefully burn virtually allof the tobacco within those smoking articles are set forth in U.S. Pat.No. 4,947,874 to Brooks et al.; U.S. Pat. No. 7,647,932 to Cantrell etal.; U.S. Pat. No. 8,079,371 to Robinson et al.; U.S. Pat. No. 7,290,549to Banerjee et al.; and U.S. Pat. App. Pub. No. 2007/0215167 to Crookset al.; the disclosures of which are incorporated herein by reference intheir entireties.

As noted, in some implementations flame/burn retardant materials andother additives that may be included within one or more of the substratematerials and may include organo-phosphorus compounds, borax, hydratedalumina, graphite, potassium tripolyphosphate, dipentaerythritol,pentaerythritol, and polyols. Others such as nitrogenous phosphonic acidsalts, mono-ammonium phosphate, ammonium polyphosphate, ammoniumbromide, ammonium borate, ethanolammonium borate, ammonium sulphamate,halogenated organic compounds, thiourea, and antimony oxides aresuitable but are not preferred agents. In each aspect offlame-retardant, burn-retardant, and/or scorch-retardant materials usedin the substrate material and/or other components (whether alone or incombination with each other and/or other materials), the desirableproperties most preferably are provided without undesirable off-gassingor melting-type behavior.

According to other implementations of the present disclosure, thesubstrate material may also incorporate tobacco additives of the typethat are traditionally used for the manufacture of tobacco products.Those additives may include the types of materials used to enhance theflavor and aroma of tobaccos used for the production of cigars,cigarettes, pipes, and the like. For example, those additives mayinclude various cigarette casing and/or top dressing components. See,for example, U.S. Pat. No. 3,419,015 to Wochnowski; U.S. Pat. No.4,054,145 to Berndt et al.; U.S. Pat. No. 4,887,619 to Burcham, Jr. etal.; U.S. Pat. No. 5,022,416 to Watson; U.S. Pat. No. 5,103,842 toStrang et al.; and U.S. Pat. No. 5,711,320 to Martin; the disclosures ofwhich are incorporated herein by reference in their entireties.Preferred casing materials may include water, sugars and syrups (e.g.,sucrose, glucose and high fructose corn syrup), humectants (e.g.glycerin or propylene glycol), and flavoring agents (e.g., cocoa andlicorice). Those added components may also include top dressingmaterials (e.g., flavoring materials, such as menthol). See, forexample, U.S. Pat. No. 4,449,541 to Mays et al., the disclosure of whichis incorporated herein by reference in its entirety. Further materialsthat may be added include those disclosed in U.S. Pat. No. 4,830,028 toLawson et al. and U.S. Pat. No. 8,186,360 to Marshall et al., thedisclosures of which are incorporated herein by reference in theirentireties.

A wide variety of types of flavoring agents, or materials that alter thesensory or organoleptic character or nature of the mainstream aerosol ofthe smoking article may be suitable to be employed. In someimplementations, such flavoring agents may be provided from sourcesother than tobacco and may be natural or artificial in nature. Forexample, some flavoring agents may be applied to, or incorporatedwithin, the substrate material and/or those regions of the smokingarticle where an aerosol is generated. In some implementations, suchagents may be supplied directly to a heating cavity or region proximateto the heat source or are provided with the substrate material. Exampleflavoring agents may include, for example, vanillin, ethyl vanillin,cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach andcitrus flavors, including lime and lemon), maple, menthol, mint,peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom,ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla,cocoa, licorice, and flavorings and flavor packages of the type andcharacter traditionally used for the flavoring of cigarette, cigar, andpipe tobaccos. Syrups, such as high fructose corn syrup, may also besuitable to be employed.

Flavoring agents may also include acidic or basic characteristics (e.g.,organic acids, such as levulinic acid, succinic acid, pyruvic acid, andbenzoic acid). In some implementations, flavoring agents may becombinable with the elements of the substrate material if desired.Example plant-derived compositions that may be suitable are disclosed inU.S. Pat. No. 9,107,453 and U.S. Pat. App. Pub. No. 2012/0152265 both toDube et al., the disclosures of which are incorporated herein byreference in their entireties. Any of the materials, such as flavorings,casings, and the like that may be useful in combination with a tobaccomaterial to affect sensory properties thereof, including organolepticproperties, such as described herein, may be combined with the substratematerial. Organic acids particularly may be able to be incorporated intothe substrate material to affect the flavor, sensation, or organolepticproperties of medicaments, such as nicotine, that may be able to becombined with the substrate material. For example, organic acids, suchas levulinic acid, lactic acid, and pyruvic acid, may be included in thesubstrate material with nicotine in amounts up to being equimolar (basedon total organic acid content) with the nicotine. Any combination oforganic acids may be suitable. For example, in some implementations, thesubstrate material may include approximately 0.1 to about 0.5 moles oflevulinic acid per one mole of nicotine, approximately 0.1 to about 0.5moles of pyruvic acid per one mole of nicotine, approximately 0.1 toabout 0.5 moles of lactic acid per one mole of nicotine, or combinationsthereof, up to a concentration wherein the total amount of organic acidpresent is equimolar to the total amount of nicotine present in thesubstrate material. Various additional examples of organic acidsemployed to produce a substrate material are described in U.S. Pat. App.Pub. No. 2015/0344456 to Dull et al., which is incorporated herein byreference in its entirety.

The selection of such further components may be variable based uponfactors such as the sensory characteristics that are desired for thesmoking article, and the present disclosure is intended to encompass anysuch further components that are readily apparent to those skilled inthe art of tobacco and tobacco-related or tobacco-derived products. See,Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp.(1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products(1972), the disclosures of which are incorporated herein by reference intheir entireties.

In other implementations, the substrate material may include othermaterials having a variety of inherent characteristics or properties.For example, the substrate material may include a plasticized materialor regenerated cellulose in the form of rayon. As another example,viscose (commercially available as VISIL®), which is a regeneratedcellulose product incorporating silica, may be suitable. Some carbonfibers may include at least 95 percent carbon or more. Similarly,natural cellulose fibers such as cotton may be suitable, and may beinfused or otherwise treated with silica, carbon, or metallic particlesto enhance flame-retardant properties and minimize off-gassing,particularly of any undesirable off-gassing components that would have anegative impact on flavor (and especially minimizing the likelihood ofany toxic off-gassing products). Cotton may be treatable with, forexample, boric acid or various organophosphate compounds to providedesirable flame-retardant properties by dipping, spraying or othertechniques known in the art. These fibers may also be treatable (coated,infused, or both by, e.g., dipping, spraying, or vapor-deposition) withorganic or metallic nanoparticles to confer the desired property offlame-retardancy without undesirable off-gassing or melting-typebehavior.

In the depicted implementation, a cross-section of the aerosol sourcemember 200 may be substantially circular such that the aerosol sourcemember 200 defines a substantially cylindrical shape extending betweenthe opposed first and second ends thereof. However, in otherimplementations, the aerosol source member 200 may define asubstantially non-circular cross-section such that the aerosol sourcemember 200 may define a substantially non-cylindrical shape between theopposed first and second ends thereof. Otherwise, in other examples, theaerosol source member 200 may comprise an asymmetric cross-section aboutthe axis.

Although not depicted in the figures, the housing 104 may include one ormore apertures therein for allowing entrance of ambient air to bedirected into the heated end 202 of the aerosol source member 200. Thus,when a consumer draws on the mouth end 204 of the aerosol source member200, air can pass into the aerosol source member 200 proximate theheated end 202, and be drawn through the inhalable substance medium forinhalation by the consumer through the mouth end 204. As will bediscussed in more detail below, in implementations wherein the overwrapis present, the drawn air may carry the inhalable substance through theoptional filter and out of an opening of the overwrap.

In some implementations, the control body 102 may include a flow sensor(not shown, e.g., a puff sensor or pressure switch). In otherimplementations, the control body 102 may alternately, or in addition,include an activation button (not shown). With respect to a flow sensor,representative current regulating components and other currentcontrolling components including various microcontrollers, sensors, andswitches for aerosol delivery devices are described in U.S. Pat. No.4,735,217 to Gerth et al., U.S. Pat. Nos. 4,922,901, 4,947,874, and4,947,875, all to Brooks et al., U.S. Pat. No. 5,372,148 to McCaffertyet al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S. Pat. No.7,040,314 to Nguyen et al., and U.S. Pat. No. 8,205,622 to Pan, all ofwhich are incorporated herein by reference in their entireties.Reference also is made to the control schemes described in U.S. Pat. No.9,423,152 to Ampolini et al., which is incorporated herein by referencein its entirety.

Still further components can be utilized in the aerosol delivery deviceof the present disclosure. For example, U.S. Pat. No. 5,154,192 toSprinkel et al. discloses indicators for smoking articles; U.S. Pat. No.5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can beassociated with the mouth-end of a device to detect user lip activityassociated with taking a draw and then trigger heating of a heatingdevice; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puffsensor for controlling energy flow into a heating load array in responseto pressure drop through a mouthpiece; U.S. Pat. No. 5,967,148 to Harriset al. discloses receptacles in a smoking device that include anidentifier that detects a non-uniformity in infrared transmissivity ofan inserted component and a controller that executes a detection routineas the component is inserted into the receptacle; U.S. Pat. No.6,040,560 to Fleischhauer et al. describes a defined executable powercycle with multiple differential phases; U.S. Pat. No. 5,934,289 toWatkins et al. discloses photonic-optronic components; U.S. Pat. No.5,954,979 to Counts et al. discloses means for altering draw resistancethrough a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.discloses specific battery configurations for use in smoking devices;U.S. Pat. No. 7,293,565 to Griffen et al. discloses various chargingsystems for use with smoking devices; U.S. Pat. No. 8,402,976 toFernando et al. discloses computer interfacing means for smoking devicesto facilitate charging and allow computer control of the device; U.S.Pat. No. 8,689,804 to Fernando et al. discloses identification systemsfor smoking devices; and PCT Pat. App. Pub. No. WO 2010/003480 by Flickdiscloses a fluid flow sensing system indicative of a puff in an aerosolgenerating system; all of the foregoing disclosures being incorporatedherein by reference in their entireties.

Further examples of components related to electronic aerosol deliverydevices and disclosing materials or components that may be used in thepresent device include U.S. Pat. No. 4,735,217 to Gerth et al.; U.S.Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977 to Higginset al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 toFelter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No.7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No.7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat. Nos.8,156,944 and 8,375,957 to Hon; U.S. Pat. No. 8,794,231 to Thorens etal.; U.S. Pat. No. 8,851,083 to Oglesby et al.; U.S. Pat. Nos. 8,915,254and 8,925,555 to Monsees et al.; U.S. Pat. No. 9,220,302 to DePiano etal.; U.S. Pat. App. Pub. Nos. 2006/0196518 and 2009/0188490 to Hon; U.S.Pat. App. Pub. No. 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub.No. 2010/0307518 to Wang; PCT Pat. App. Pub. No. WO 2010/091593 to Hon;and PCT Pat. App. Pub. No. WO 2013/089551 to Foo, each of which isincorporated herein by reference in its entirety. Further, U.S. patentapplication Ser. No. 14/881,392 to Worm et al., filed Oct. 13, 2015,discloses capsules that may be included in aerosol delivery devices andfob-shape configurations for aerosol delivery devices, and isincorporated herein by reference in its entirety. A variety of thematerials disclosed by the foregoing documents may be incorporated intothe present devices in various implementations, and all of the foregoingdisclosures are incorporated herein by reference in their entireties.

In some implementations, an input element may be included with theaerosol delivery device (and may replace or supplement an airflow orpressure sensor). The input element may be included to allow a user tocontrol functions of the device and/or for output of information to auser. Any component or combination of components may be utilized as aninput element for controlling the function of the device. For example,one or more pushbuttons may be used as described in U.S. Pub. No.2015/0245658 to Worm et al., which is incorporated herein by reference.Likewise, a touchscreen may be used as described in U.S. patentapplication Ser. No. 14/643,626, filed Mar. 10, 2015, to Sears et al.,which is incorporated herein by reference. As a further example,components adapted for gesture recognition based on specified movementsof the aerosol delivery device may be used as an input. See U.S. Pub.2016/0158782 to Henry et al., which is incorporated herein by reference.As still a further example, a capacitive sensor may be implemented onthe aerosol delivery device to enable a user to provide input, such asby touching a surface of the device on which the capacitive sensor isimplemented.

As noted, the aerosol delivery device 100 of the depicted implementationalso includes a heating assembly 110, which receives power from theelectrical energy source 108 and, in some implementations, may becontrolled by the control component 106. In various implementations, theheating assembly 110 may include a heating member that may be any devicesuitable to provide heat sufficient to facilitate release of theinhalable substance for inhalation by a consumer. In certainimplementations, the electrical heating member may be a resistanceheating member. Useful heating members can be those having low mass, lowdensity, and moderate resistivity and that are thermally stable at thetemperatures experienced during use. Useful heating members heat andcool rapidly, and thus provide for the efficient use of energy. Rapidheating of the element also provides almost immediate volatilization ofthe aerosol-forming substance. Rapid cooling prevents substantialvolatilization (and hence waste) of the aerosol-forming substance duringperiods when aerosol formation is not desired. Such heating members alsopermit relatively precise control of the temperature range experiencedby the aerosol-forming substance, especially when time based currentcontrol is employed. Useful heating members also are chemicallynon-reactive (and chemically non-catalytic) with the materialscomprising the inhalable substance medium being heated so as not toadversely affect the flavor or content of the aerosol or vapor that isproduced. Example, non-limiting, materials that may comprise the heatingmember include a variety of metal and ceramic materials. Other specificnon-limiting examples include carbon, graphite, carbon/graphitecomposites, metallic and non-metallic carbides, nitrides, silicides,inter-metallic compounds, cermets, metal alloys, and metal foils. Inparticular, refractory materials may be useful. Various, differentmaterials can be mixed to achieve the desired properties of resistivity,mass, thermal conductivity, and surface properties.

In some implementations, the heating member may be provided in otherforms, such as in the form of a foil, a foam, a mesh, a hollow ball, ahalf ball, discs, spirals, fibers, wires, films, yarns, strips, ribbons,or cylinders. Such heating members often comprise a metal material andare configured to produce heat as a result of the electrical resistanceassociated with passing an electrical current therethrough. Suchresistive heating elements may be positioned in proximity to, and/or indirect contact with, the substrate portion. The heating assembly or theheating member may be located in the control body and/or the aerosolsource member, as will be discussed in more detail below. In variousimplementations, the substrate portion may include components (i.e.,heat conducting constituents) that are imbedded in, or otherwise partof, the substrate portion that may serve as, or facilitate the functionof, the heating assembly. Some examples of various heating members andelements are described in U.S. Pat. No. 9,078,473 to Worm et al., thedisclosure of which is incorporated herein by reference in its entirety.

Some non-limiting examples of various heating member configurationsinclude configurations in which a heating member or element is placed inproximity with an aerosol source member. For instance, in some examples,at least a portion of a heating member may surround at least a portionof an aerosol source member. In other examples, one or more heatingmembers may be positioned adjacent an exterior of an aerosol sourcemember when inserted in a control body. In other examples, at least aportion of a heating member may penetrate at least a portion of anaerosol source member (such as, for example, one or more prongs and/orspikes that penetrate an aerosol source member), when the aerosol sourcemember is inserted into the control body.

Various embodiments of materials configured to produce heat whenelectrical current is applied therethrough may be employed to form theheating member. Example materials from which the wire coil may be formedinclude Kanthal (FeCrAl), nichrome, nickel, stainless steel, indium tinoxide, tungsten, molybdenum disilicide (MoSi₂), molybdenum silicide(MoSi), molybdenum disilicide doped with aluminum (Mo(Si,Al)₂),titanium, platinum, silver, palladium, alloys of silver and palladium,graphite and graphite-based materials (e.g., carbon-based foams andyarns), conductive inks, boron doped silica, and ceramics (e.g.,positive or negative temperature coefficient ceramics). The heatingmember may be resistive heating member or a heating member configured togenerate heat through induction. The heating member may be coated byheat conductive ceramics such as aluminum nitride, silicon carbide,beryllium oxide, alumina, silicon nitride, or their composites.

As will be discussed in more detail below, in some of the depictedimplementations a plurality of spikes serve as the heating member. Inother of the depicted implementations, a plurality of spaced bands serveas the heating member in addition to the plurality of spikes or as analternate to the plurality of spikes.

As shown in FIG. 1 , the heating assembly 110 includes a plurality ofspikes 112 that are configured to articulate between a retractedposition, in which the spikes are not in contact with aerosol sourcemember, and a heating position, in which spikes contact the aerosolsource member 200. In particular, FIG. 1 shows the spikes 112 in aheating position. In various implementations of the heating position,the spikes not only contact the aerosol source member 200 but alsopierce through the outer surface 206 of the aerosol source member 200such that a portion of the spikes 112 extends into the substratematerial 210. In various implementations, the degree to which the spikes112 extend into the substrate material may vary. For example, in someimplementations the spikes 112 may extend into the substrate material asmall distance, while in other implementations the spikes 112 may extendto the center of the substrate material 210, and in still otherimplementations, the spikes 112 may extend through the center of thesubstrate material 210.

In various implementations, the plurality of spikes 112 may compriseopposing rows of spikes 112, such as those illustrated in FIGS. 1 and 2, with one row being positioned on one side of the aerosol source member200, and the other row being positioned on an opposite side of theaerosol source member 200. It should be noted that in someimplementations, there may be additional rows of spikes 112, such as,for example, three or more rows that may be positioned around acircumference of the heated end 202 of the aerosol source member 200. Inother implementations, however, there may be a single row of spikes 112.In some implementations, the positioning of the individual spikes 112may be staggered between the rows, such as those illustrated in FIGS. 1and 2 , while in other implementations the positioning of the individualspikes 112 may be substantially aligned. In various implementations,articulation of the plurality of spikes 112 may occur in different ways.For example, in some implementations the plurality of spikes 112 may becontained in a clamshell housing that moves away from the aerosol sourcemember 200 in the retracted position and toward the aerosol sourcemember 200 in the heating position. In some implementations, activationof the articulating motion may be triggered by a button. For example, insome implementations the clamshell housing may be spring-loaded, and abutton may trigger the clamshell housing to move from the retractedposition to the heating position. In another implementation, a user mayslide a feature that carries one or both of the rows of spikes 112 fromthe retracted position to the heating position, in which the spikes 112pierce through the outer surface 206 of the substrate material and intoa portion of the interior area 208 thereof. It should be noted thatalthough in the implementations shown in the figures, the spikes havebeen schematically illustrated as having a substantially cone-likeshape, in various other implementations the spikes may have a variety ofother shapes configured to allow the spikes to pierce the aerosol sourcemember, including for example, a substantially cylindrical shape, asubstantially prismatic shape, a substantially cuboidal shape, etc.

In various implementations, a heating member of the heating assembly 110may generate heat upon receiving electrical energy from the electricalenergy source 108. In such a manner, in some implementations theplurality of spikes 112 may comprise a resistive heating member thatheats the substrate material 210 via contact with the substrate material210. Because the plurality of spikes 112 extends into a portion of theinterior area 208 of the substrate material 210, the substrate material210 of the depicted implementation is heated from the inside outward.Direct contact may be preferred in light of the ability to provideconduction heating that is more rapid and that requires less thermalresistance. In various implementations, the plurality of spikes 112 maybe constructed of a heat conducting material. For example, in someimplementations the plurality of spikes 112 are chemically non-reactivewith the materials comprising the substrate material being heated so asnot to adversely affect the flavor or content of the aerosol or vaporthat is produced. As noted above, example, non-limiting, materials thatmay comprise the plurality of spikes 112 include carbon, graphite,carbon/graphite composites, metallic and non-metallic carbides,nitrides, silicides, inter-metallic compounds, cermets, and metalalloys. In some implementations, metal foils may be used.

In some implementations, additional heating members may be used. Forexample, some additional heating members may have other shapes thatcorrespond to the shape of the substrate material in the aerosol sourcemember. Other examples of heater arrays that could be adapted for use inthe present disclosure per the discussion provided above can be found inU.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No. 5,093,894 toDeevi et al.; U.S. Pat. No. 5,224,498 to Deevi et al.; U.S. Pat. No.5,228,460 to Sprinkel Jr., et al.; U.S. Pat. No. 5,322,075 to Deevi etal.; U.S. Pat. No. 5,353,813 to Deevi et al.; U.S. Pat. No. 5,468,936 toDeevi et al.; U.S. Pat. No. 5,498,850 to Das; U.S. Pat. No. 5,659,656 toDas; U.S. Pat. No. 5,498,855 to Deevi et al.; U.S. Pat. No. 5,530,225 toHajaligol; U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat. No. 5,573,692to Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhauer et al., whichare incorporated herein by reference in their entireties.

FIG. 3 illustrates a perspective schematic view of a heated end 302 ofan aerosol source member and a portion of a heating assembly, accordingto another example implementation of the present disclosure. Inparticular, the heated end 302 of the aerosol source member defines anouter surface 306 and an interior area 308. In the depictedimplementation, a substrate material 310 is located in the interior area308 of the heated end 302 of the aerosol source member. As noted above,in some implementations, substrate material may be located in both theheated end 302 and the mouth end of the aerosol source member. In thedepicted implementation, the substrate material 310 has a singlesegment, although in other implementations the substrate material 310may include additional segments, which may have different compositions.In various implementations, one or more of the substrate materials mayinclude a tobacco or tobacco related material, with an aerosol precursorcomposition associated therewith. In other implementations, non-tobaccomaterials may be used, such as a cellulose pulp material. In otherimplementations, the non-tobacco substrate material may not be aplant-derived material. Reference is made to the possible substratematerials, compositions, components, and/or additives for use in asubstrate material (and/or multiple substrate materials) above.

As described above, heating of the substrate material 310 results inaerosolization of the aerosol precursor composition associated with thesubstrate material 310. In various implementations, the mouth end of theaerosol source member is configured to receive the generated aerosoltherethrough in response to a draw applied to the mouth end by a user.In some implementations, the mouth end of the aerosol source member mayinclude a filter configured to receive the aerosol therethrough inresponse to the draw applied to the mouth end of the aerosol sourcemember. Preferably, the elements of the substrate material 310 do notexperience thermal decomposition (e.g., charring, scorching, or burning)to any significant degree, and the aerosolized components are entrainedin the air that is drawn through the aerosol delivery device 100,including a filter (if present), and into the mouth of the user.

As shown in FIG. 3 , the heating assembly of the depicted implementationincludes a plurality of spikes 112 that are configured to articulatebetween a retracted position, in which the spikes are not in contactwith aerosol source member, and a heating position, in which spikescontact the aerosol source member. In particular, FIG. 3 shows thespikes 112 in a heating position. In various implementations of theheating position, the spikes 112 not only contact the aerosol sourcemember but also pierce through the outer surface 306 of the aerosolsource member such that a portion of the spikes 112 extends into thesubstrate material 310. In various implementations, the degree to whichthe spikes 112 extend into the substrate material may vary. For example,in some implementations the spikes 112 may extend into the substratematerial a small degree, while in other implementations the spikes 112may extend to the center of the substrate material 310, and in stillother implementations, the spikes 112 may extend through the center ofthe substrate material 310.

In various implementations, the plurality of spikes 112 may compriseopposing rows of spikes 112, such as those illustrated in FIG. 3 , withone row being positioned on one side of the aerosol source member, andthe other row being positioned on an opposite side of the aerosol sourcemember. It should be noted that in some implementations, there may beadditional rows of spikes 112, such as, for example, three or more rowsthat may be positioned around a circumference of the heated end 302 ofthe aerosol source member. In other implementations, however, there maybe a single row of spikes 112. In some implementations, the positioningof the individual spikes 112 may be staggered between the rows, such asthose illustrated in FIG. 3 , while in other implementations thepositioning of the individual spikes 112 may be substantially aligned.As noted above, in various implementations articulation of the pluralityof spikes 112 may occur in different ways. For example, in someimplementations the plurality of spikes 112 may be contained in aclamshell housing that moves away from the aerosol source member in theretracted position and toward the aerosol source member in the heatingposition. In some implementations, activation of the articulating motionmay be triggered by a button. For example, in some implementations theclamshell housing may be spring-loaded, and a button may trigger theclamshell housing to move from the retracted position to the heatingposition. In another implementation, a user may slide a feature thatcarries one or both of the rows spikes 112 from the retracted positionto the heating position, in which the spikes 112 pierce through theouter surface of the substrate material and into a portion of theinterior area 308 thereof.

In various implementations, a heating member of the heating assembly maygenerate heat upon receiving electrical energy from the electricalenergy source. In such a manner, in some implementations the pluralityof spikes 112 may comprise a resistive heating member that heats thesubstrate material 310 via a supplemental heat conducting material inaddition to contact with the substrate material 310. In the depictedimplementation, the supplemental heat conducting material comprises aplurality of spaced conductive bands 320. In such a manner, in additionto, or as an alternative to, heating of the substrate material 310 viathe spikes 112 themselves, the substrate material 310 may be heated bythe plurality of spaced conductive bands 320 via heat conduction fromthe plurality of spikes 112. In some implementations, the plurality ofconductive bands 320 may be constructed of a metal material, such as,but not limited to, copper, aluminum, platinum, gold, silver, iron,steel, brass, bronze, or any combination thereof. In otherimplementations, the plurality of conductive bands 320 may beconstructed of a coated metal, such as, for example, aluminum-coatedcopper or other combinations of coatings and base materials chosen fromthe list above. In still other implementations, the plurality ofconductive bands 320 may be constructed of a ceramic material, such as,but not limited to, aluminum oxide, beryllium oxide, boron nitride,silicon carbide, silicon nitride, aluminum nitride, or any combinationthereof. In still other implementations, the plurality of conductivebands 320 may be constructed of a carbon material, such as, but notlimited to, graphite, graphene, carbon nanotubes, nanoribbons,diamond-like structured carbon materials, or combinations thereof. Instill other implementations, the plurality of conductive bands 320 maybe constructed of polymer composites, such as polymer materials withmetal, ceramic, or carbon fibers. For example, some implementations maycomprise polyimide, epoxy, or silicone polymers, with boron nitride,zinc oxide, or alumina fibers. In further implementations, the presentdisclosure contemplates that the plurality of conductive bands 320 maybe constructed of any one or any combination of the above materials, orcomposites that include two or more of the above materials.

FIG. 4 illustrates a perspective schematic view of a heated end 402 ofan aerosol source member; FIG. 5 illustrates a perspective schematicview of the heated end 402 of the aerosol source member and a portion ofa heating assembly; and FIG. 6 illustrates a top schematic view of theheated end of the aerosol source member and a portion of the heatingassembly, according to other example implementations of the presentdisclosure. In the depicted implementation, the heated end 402 of theaerosol source member defines a first outer surface 406 and a firstinterior area 408, with a first substrate material 410 located in thefirst interior area 408 of the heated end 402 of the aerosol sourcemember. As noted above, in some implementations, substrate material maybe located in both the heated end 402 and the mouth end of the aerosolsource member. In the depicted implementation, the first substratematerial 410 has a single segment, although in other implementations thefirst substrate material 410 may include additional segments, which mayhave different compositions. In various implementations, the firstsubstrate material 410 may include a tobacco or tobacco relatedmaterial, with an aerosol precursor composition associated therewith. Inother implementations, non-tobacco materials may be used, such as acellulose pulp material. In other implementations, the non-tobaccosubstrate material may not be a plant-derived material. Reference ismade to the possible substrate materials, compositions, components,and/or additives for use in a substrate material (and/or multiplesubstrate materials) above.

The depicted implementation also includes a second substrate material412, which substantially surrounds the first substrate material 410. Inparticular, the second substrate material 412 of the depictedimplementation is positioned proximate the first outer surface 406 ofthe first substrate material 410 and defines its own second outersurface 416 and second interior area 418. As with the first substratematerial 410, in the depicted implementation the second substratematerial 412 has a single segment, although in other implementations thesecond substrate material 412 may include additional segments, which mayhave different compositions. In various implementations, the secondsubstrate material 412 may include a tobacco or tobacco relatedmaterial, with an aerosol precursor composition associated therewith. Inother implementations, non-tobacco materials may be used, such as acellulose pulp material. In other implementations, the non-tobaccosubstrate material may not be a plant-derived material. Reference ismade to the possible substrate materials, compositions, components,and/or additives for use in a substrate material (and/or multiplesubstrate materials) above. While in some implementations, the firstsubstrate material 410 and the second substrate material 412 maycomprise the same material, in various other implementations, the firstsubstrate material 410 and the second substrate material 412 maycomprise different materials. For example, in some implementations thefirst substrate material 410 and the second substrate material 412 mayinclude one or more respective components that are desired to be keptseparate. For example, in one implementation one of the substratematerials may include an ionized calcium (e.g., Ca++) component and theother substrate material may include an alginate component.

As described above, heating of the first substrate material 410 and/orthe second substrate material 412 results in aerosolization of aerosolprecursor composition(s) associated with the substrate materials 410,412. In various implementations, the mouth end of the aerosol sourcemember is configured to receive the generated aerosol therethrough inresponse to a draw applied to the mouth end by a user. In someimplementations, the mouth end of the aerosol source member may includea filter configured to receive the aerosol therethrough in response tothe draw applied to the mouth end of the aerosol source member.Preferably, the elements of the substrate materials 410, 412 do notexperience thermal decomposition (e.g., charring, scorching, or burning)to any significant degree, and the aerosolized components are entrainedin the air that is drawn through the aerosol delivery device 100,including a filter (if present), and into the mouth of the user.

As shown in FIGS. 5 and 6 , the heating assembly of the depictedimplementation includes a plurality of spikes 112 that are configured toarticulate between a retracted position, in which the spikes 112 are notin contact with aerosol source member, and a heating position, in whichspikes 112 contact the aerosol source member. In particular, FIGS. 5 and6 show the spikes 112 in a heating position. In various implementationsof the heating position, the spikes 112 not only contact the aerosolsource member but also pierce through the second outer surface 416 ofthe aerosol source member such that a portion of the spikes 112 extendsinto the second substrate material 412. In some implementations, thespikes 112 extend only into the second substrate material 412 and notinto the first substrate material 410. In such implementations, thedistance to which the spikes 112 extend into the second substratematerial 412 may vary. For example, in some implementations the spikes112 may extend into the second substrate material 412 a short distance,while in other implementations the spikes 112 may extend to the centerof the second substrate material 412, and in still otherimplementations, the spikes 112 may extend through the second substratematerial 412. In the depicted implementation, the spikes 112 extendthrough the second substrate material 412 and further extend through thefirst outer surface 406 and into the first substrate material 410. Insuch implementations, the extent to which the spikes 112 extend into thefirst substrate material 410 may vary. For example, in someimplementations the spikes 112 may extend into the first substratematerial 410 a short distance, while in other implementations the spikes112 may extend to the center of the first substrate material 410, and instill other implementations, the spikes 112 may extend through thecenter of the first substrate material 410.

In various implementations, the plurality of spikes 112 may compriseopposing rows of spikes 112, such as those illustrated in FIG. 5 , withone row being positioned on one side of the aerosol source member, andthe other row being positioned on an opposite side of the aerosol sourcemember. It should be noted that in some implementations, there may beadditional rows of spikes 112, such as, for example, three or more rowsthat may be positioned around a circumference of the heated end 402 ofthe aerosol source member. In other implementations, however, there maybe a single row of spikes 112. In some implementations, the positioningof the individual spikes 112 may be staggered between the rows, such asthose illustrated in FIG. 5 , while in other implementations thepositioning of the individual spikes 112 may be substantially aligned.As noted above, in various implementations articulation of the pluralityof spikes 112 may occur in different ways. For example, in someimplementations the plurality of spikes 112 may be contained in aclamshell housing that moves away from the aerosol source member in theretracted position and toward the aerosol source member in the heatingposition. In some implementations, activation of the articulating motionmay be triggered by a button. For example, in some implementations theclamshell housing may be spring-loaded, and a button may trigger theclamshell housing to move from the retracted position to the heatingposition. In another implementation, a user may slide a feature thatcarries one or both of the rows spikes 112 from the retracted positionto the heating position, in which the spikes 112 pierce through an outersurface of a substrate material and into a portion of an interior area408 thereof.

As noted above, in various implementations a heating member of theheating assembly may generate heat upon receiving electrical energy fromthe electrical energy source. In such a manner, in some implementationsthe plurality of spikes 112 may comprise a resistive heating member thatheats the first and second substrate materials 410, 412 via asupplemental heat conducting material in addition to contact with thesubstrate materials 410, 412 themselves. In the depicted implementation,the supplemental heat conducting material comprises a plurality ofspaced conductive bands 420 that are located between the first outersurface 406 of the first substrate material 410 and an inner surface ofthe second substrate material 412. In such a manner, in addition to, oras an alternative to, heating of the first and second substratematerials 410, 412 via the spikes 112 themselves, the first and secondsubstrate materials 410, 412 may be heated by the plurality of spacedconductive bands 420 via heat conduction from the plurality of spikes112. In some implementations, the plurality of spaced conductive bands420 may be constructed of a metal material, such as, but not limited to,copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, orany combination thereof. In other implementations, the plurality ofconductive bands 420 may be constructed of a coated metal, such as, forexample, aluminum-coated copper or other combinations of coatings andbase materials chosen from the list above. In still otherimplementations, the plurality of spaced conductive bands 420 may beconstructed of a ceramic material, such as, but not limited to, aluminumoxide, beryllium oxide, boron nitride, silicon carbide, silicon nitride,aluminum nitride, or any combination thereof. In still otherimplementations, the plurality of heat conductive bands 420 may beconstructed of a carbon material, such as, but not limited to, graphite,graphene, carbon nanotubes, nanoribbons, diamond-like structured carbonmaterials, or combinations thereof. And in still other implementations,the plurality of heat conductive bands 420 may be constructed of polymercomposites, such as polymer materials with metal, ceramic, or carbonfibers, including, but not limited to, polyimide, epoxy, or siliconepolymers, with boron nitride, zinc oxide, or alumina fibers. In furtherimplementations, the present disclosure contemplates that the pluralityof conductive bands may be constructed of any one or any combination ofthe above materials, or composites that include two or more of the abovematerials.

It should be noted that while in in the depicted implementationssubstrate material resides under the conductive bands as well as betweenthe conductive bands, in other implementations, aerosol source materialmay reside solely under the conductive bands, or, in otherimplementations, solely between the conductive bands. In addition, whileion the depicted implementations the concentration of the aerosolgenerating material in the substrate material is relatively consistentthroughout the segments, in some implementations, the concentration ofthe aerosol generating materials in the substrate material may vary fromsegment to segment.

FIG. 7 illustrates a perspective schematic drawing of a portion of aheated end 502 of an aerosol source member and a portion of a heatingassembly, and FIG. 8 illustrates a top schematic view of the heated end502 of the aerosol source member and a portion of the heating assembly,according to an example implementation of the present disclosure. Inparticular, the heated end 502 of the aerosol source member defines afirst outer surface 506 and a first interior area 508, with a firstsubstrate material 510 located in the first interior area 508 of theheated end 502 of the aerosol source member. As noted above, in someimplementations, substrate material may be located in both the heatedend 502 and the mouth end of the aerosol source member. In the depictedimplementation, the first substrate material 510 has a single segment,although in other implementations the first substrate material 510 mayinclude additional segments, which may have different compositions. Invarious implementations, the first substrate material 510 may include atobacco or tobacco related material, with an aerosol precursorcomposition associated therewith. In other implementations, non-tobaccomaterials may be used, such as a cellulose pulp material. In otherimplementations, the non-tobacco substrate material may not be aplant-derived material. Reference is made to the possible substratematerials, compositions, components, and/or additives for use in asubstrate material (and/or multiple substrate materials) above.

The depicted implementation also includes a second substrate material512, which substantially surrounds the first substrate material 510. Inparticular, the second substrate material 512 of the depictedimplementation is positioned proximate the first outer surface 506 ofthe first substrate material 510 and defines its own second outersurface 516 and second interior area 518. As with the first substratematerial 510, in the depicted implementation the second substratematerial 512 has a single segment, although in other implementations thesecond substrate material 510 may include additional segments, which mayhave different compositions. In various implementations, the secondsubstrate material 512 may include a tobacco or tobacco relatedmaterial, with an aerosol precursor composition associated therewith. Inother implementations, non-tobacco materials may be used, such as acellulose pulp material. In other implementations, the non-tobaccosubstrate material may not be a plant-derived material. Reference ismade to the possible substrate materials, compositions, components,and/or additives for use in a substrate material (and/or multiplesubstrate materials) above. While in some implementations, the firstsubstrate material 510 and the second substrate material 512 maycomprise the same material, in various other implementations, the firstsubstrate material 510 and the second substrate material 512 maycomprise different materials. For example, in some implementations thefirst substrate material 510 and the second substrate material 512 mayinclude one or more respective components that are desired to be keptseparate. For example, in one implementation one of the substratematerials may include an ionized calcium (e.g., Ca++) component and theother substrate material may include an alginate component.

As described above, heating of the first substrate material 510 and/orthe second substrate material 512 results in aerosolization of aerosolprecursor composition(s) associated with the substrate materials 510,512. In various implementations, the mouth end of the aerosol sourcemember is configured to receive the generated aerosol therethrough inresponse to a draw applied to the mouth end by a user. In someimplementations, the mouth end of the aerosol source member may includea filter configured to receive the aerosol therethrough in response tothe draw applied to the mouth end of the aerosol source member.Preferably, the elements of the substrate materials 510, 512 do notexperience thermal decomposition (e.g., charring, scorching, or burning)to any significant degree, and the aerosolized components are entrainedin the air that is drawn through the aerosol delivery device 100,including a filter (if present), and into the mouth of the user.

As shown in FIGS. 7 and 8 , the heating assembly of the depictedimplementation includes a plurality of spikes 112 that are configured toarticulate between a retracted position, in which the spikes 112 are notin contact with aerosol source member, and a heating position, in whichspikes 112 contact a plurality of spaced conductive bands 520 thatextend around a limited portion of the outer surface of the firstsubstrate material 510. In particular, FIGS. 7 and 8 show the spikes 112in a heating position. In the depicted implementation, the plurality ofspaced conductive bands 520 serves as the heating member. In particular,each of the plurality of spaced conductive bands 520 of the depictedimplementation defines a first end 520 a and a second end 520 b. In sucha manner, when the plurality of spikes 112, which are electricallyconnected to an electrical energy source 108, contacts respective firstand second ends 520 a, 520 b of the plurality of spaced conductive bands520, a plurality of resistive heating circuits are completed such thatthe plurality of spaced conductive bands 520 serves as the heatingmember.

In some implementations, the plurality of spaced conductive bands 520may be constructed of a metal material, such as, but not limited to,copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, orany combination thereof. In other implementations, the plurality ofconductive bands 520 may be constructed of a coated metal, such as, forexample, aluminum-coated copper or other combinations of coatings andbase materials chosen from the list above. In still otherimplementations, the plurality of spaced conductive bands 520 may beconstructed of a ceramic material, such as, but not limited to, aluminumoxide, beryllium oxide, boron nitride, silicon carbide, silicon nitride,aluminum nitride, or any combination thereof. In still otherimplementations, the plurality of heat conductive bands 520 may beconstructed of a carbon material, such as, but not limited to, graphite,graphene, carbon nanotubes, nanoribbons, diamond-like structured carbonmaterials, or combinations thereof. And in still other implementations,the plurality of heat conductive bands 520 may be constructed of polymercomposites, such as polymer materials with metal, ceramic, or carbonfibers, including, but not limited to, polyimide, epoxy, or siliconepolymers, with boron nitride, zinc oxide, or alumina fibers. In furtherimplementations, the present disclosure contemplates that the pluralityof conductive bands may be constructed of any one or any combination ofthe above materials, or composites that include two or more of the abovematerials.

In some implementations of the heating position, the spikes 112 not onlycontact the aerosol source member but also pierce through the secondouter surface 516 of the aerosol source member such that a portion ofthe spikes 112 extends into the second substrate material 512. In someimplementations, the spikes 112 extend only into the second substratematerial 512 and not into the first substrate material 510. In suchimplementations, the distance to which the spikes 112 extend into thesecond substrate material 512 may vary. For example, in someimplementations the spikes 112 may extend into the second substratematerial 512 a short distance, while in other implementations the spikes112 may extend to the center of the second substrate material 512, andin still other implementations, the spikes 112 may extend through thesecond substrate material 512. For example, in the depictedimplementation the spikes 112 extend through the second substratematerial 512 and further extend through the first outer surface 506 andinto the first substrate material 510. In such implementations, theextent to which the spikes 112 extend into the first substrate material510 may vary. For example, in some implementations the spikes 112 mayextend into the first substrate material 510 a short distance, while inother implementations the spikes 112 may extend to the center of thefirst substrate material 510, and in still other implementations, thespikes 112 may extend through the center of the first substrate material510.

In various implementations, the plurality of spikes 112 may comprise apair of rows of spikes 112, such as those illustrated in FIG. 7 , withone row being positioned proximate the other row on the same side of theaerosol source member. In the depicted implementation, the rows ofspikes 112 are substantially aligned; however, in other implementations,such as, for example, an implementation in which the spaced conductivebands have a spiral pattern around the substrate material, the rows ofspikes may be staggered. It should be noted, however, that for any ofthe implementations discussed herein the plurality of spikes need not bearranged in a pattern, and thus, in some implementations, the pluralityof spikes may be distributed randomly. As noted above, in variousimplementations articulation of the plurality of spikes 112 may occur indifferent ways. For example, in some implementations the plurality ofspikes 112 may be contained in a clamshell housing that moves away fromthe aerosol source member in the retracted position and toward theaerosol source member in the heating position. In some implementations,activation of the articulating motion may be triggered by a button. Forexample, in some implementations the clamshell housing may bespring-loaded, and a button may trigger the clamshell housing to movefrom the retracted position to the heating position. In anotherimplementation, a user may slide a feature that carries one or both ofthe rows spikes from the retracted position to the heating position, inwhich the heat conducting spikes 112 pierce through an outer surface ofa substrate material and into a portion of an interior area 508 thereof.

For any of the implementations described above, the control component106 and/or the plurality of spikes 112 may be configured such thatsubstrate material (e.g., a first substrate material or first and secondsubstrate materials) may be heated in segments. In such a manner, theplurality of spikes 112 may be configured to be independentlycontrollable. For example, in some implementations individual spikes112, pairs of spikes 112, and/or groups of spikes 112 may beindependently controllable such that various portions of the substratematerial may be heated at different times. In one implementation,individual spikes 112, pairs of spikes 112, and/or groups of spikes 112may be independently activated (e.g., independently articulated and/orindependently heated and/or independently connected to an electricalenergy source) so that the substrate material is sequentially heated.This could occur via heating from the spikes and/or the conductivebands, as described above. In such implementations, activation of thespikes 112 may be initiated by the puffing action of the consumerthrough the use of one or more various sensors, as otherwise describedherein, and/or may be initiated once the puff is discontinued as sensedby one or more various sensors, such as a button. Thus, in someimplementations, a number of possible heating segments may correspond toa number of puffs available from the aerosol source member 200. In someimplementations, a single aerosol source member may provide about 4 toabout 12, about 5 to about 11, or about 6 to about 10 puffs,

It should be noted that although the aerosol source member and controlbody of the present disclosure may be provided together as a completesmoking article or pharmaceutical delivery article generally, thecomponents also may be provided separately. For example, the presentdisclosure also encompasses a disposable unit for use with a reusablesmoking article or a reusable pharmaceutical delivery article. Inspecific implementations, such a disposable unit (which may be anaerosol source member as illustrated in the appended figures) cancomprise a substantially tubular shaped body having a heated endconfigured to engage the reusable smoking article or pharmaceuticaldelivery article, an opposing mouth end configured to allow passage ofan inhalable substance to a consumer, and a wall with an outer surfaceand an inner surface that defines an interior space. Variousimplementations of an aerosol source member (or cartridge) are describedin U.S. Pat. No. 9,078,473 to Worm et al., which is incorporated hereinby reference.

In addition to the disposable unit, the present disclosure may furtherbe characterized as providing a separate control body for use in areusable smoking article or a reusable pharmaceutical delivery article.In specific implementations, the control body may generally be a housinghaving a receiving end (which may include a receiving chamber with anopen end) for receiving a heated end of a separately provided aerosolsource member. The control body may further include an electrical energysource that provides power to an electrical heating member, which may bea component of the control body or may be included in aerosol sourcemember to be used with the control unit. In various implementations, thecontrol body may also include further components, including anelectrical power source (such as a battery), components for actuatingcurrent flow into the heating member, and components for regulating suchcurrent flow to maintain a desired temperature for a desired time and/orto cycle current flow or stop current flow when a desired temperaturehas been reached or the heating member has been heating for a desiredlength of time. In some implementations, the control unit further maycomprise one or more pushbuttons associated with one or both of thecomponents for actuating current flow into the heating member, and thecomponents for regulating such current flow. The control body may alsoinclude one or more indicators, such as lights indicating the heater isheating and/or indicating the number of puffs remaining for an aerosolsource member that is used with the control body.

Although the various figures described herein illustrate the controlbody and aerosol source member in a working relationship, it isunderstood that the control body and the aerosol source member may existas individual devices. Accordingly, any discussion otherwise providedherein in relation to the components in combination also should beunderstood as applying to the control body and the aerosol source memberas individual and separate components.

In another aspect, the present disclosure may be directed to kits thatprovide a variety of components as described herein. For example, a kitmay comprise a control body with one or more aerosol source members. Akit may further comprise a control body with one or more chargingcomponents. A kit may further comprise a control body with one or morebatteries. A kit may further comprise a control body with one or moreaerosol source members and one or more charging components and/or one ormore batteries. In further implementations, a kit may comprise aplurality of aerosol source members. A kit may further comprise aplurality of aerosol source members and one or more batteries and/or oneor more charging components. In the above implementations, the aerosolsource members or the control bodies may be provided with a heatingmember inclusive thereto. The inventive kits may further include a case(or other packaging, carrying, or storage component) that accommodatesone or more of the further kit components. The case could be a reusablehard or soft container. Further, the case could be simply a box or otherpackaging structure.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

The invention claimed is:
 1. An aerosol delivery device comprising: anaerosol source member that defines an outer surface and an interior areaand includes a substrate material having an aerosol precursorcomposition associated therewith; a control body having a housing thatis configured to receive the aerosol source member; an electrical energysource coupled with the housing; and a plurality of spikes comprising aheating assembly connected to the electrical energy source, theplurality of spikes extending along a longitudinal axis parallel to theaerosol source member, wherein the plurality of spikes are configured toarticulate between a retracted position, in which the plurality ofspikes are not in contact with the aerosol source member, and a heatingposition, in which the plurality of spikes pierce through the outersurface of the substrate material and into a portion of the interiorarea thereof.
 2. The aerosol delivery device of claim 1, wherein theouter surface of the substrate material includes a plurality of spacedconductive bands.
 3. The aerosol delivery device of claim 2, whereineach of the spaced conductive bands circumscribes the entire outersurface of the substrate material.
 4. The aerosol delivery device ofclaim 2, wherein each of the spaced conductive bands extends around alimited portion of the outer surface of the substrate material anddefines a first end and a second end.
 5. The aerosol delivery device ofclaim 4, wherein in the heating position, respective spikes of theplurality of heat conducting spikes contact the first and second ends ofthe spaced conductive bands.
 6. The aerosol delivery device of claim 5,wherein the plurality of spaced conductive bands comprises a heatingmember of the heating assembly.
 7. The aerosol delivery device of claim1, wherein the plurality of spikes comprises a heating member of theheating assembly.
 8. The aerosol delivery device of claim 1, wherein theaerosol source member further comprises a second substrate material thatdefines an outer surface and an interior area, and wherein the secondsubstrate material surrounds the first substrate material.
 9. Theaerosol delivery device of claim 8, wherein the outer surface of thefirst substrate material includes a plurality of spaced conductivebands.
 10. The aerosol delivery device of claim 9, wherein each of thespaced conductive bands circumscribes the entire outer surface of thesubstrate material.
 11. The aerosol delivery device of claim 9, whereineach of the spaced conductive bands extends around a portion of theouter surface of the substrate material and defines a first end and asecond end.
 12. The aerosol delivery device of claim 11, wherein in theheating position, respective spikes of the plurality of spikes contactthe first and second ends of the spaced conductive bands.
 13. Theaerosol delivery device of claim 12, wherein the plurality of spacedconductive bands comprises a heating member of the heating assembly. 14.The aerosol delivery device of claim 9, wherein the plurality of spikescomprises a heating member of the heating assembly.
 15. The aerosoldelivery device of claim 8, wherein the first substrate materialcomprises a first composition, wherein the second substrate materialcomprises a second composition, and wherein the first composition isdifferent than the second composition.
 16. The aerosol delivery deviceof claim 8, wherein the first substrate material comprises at least oneof shreds of tobacco material, beads of tobacco material, an extrudedstructure of tobacco material, a crimped sheet of tobacco material, andcombinations thereof.
 17. The aerosol delivery device of claim 8,wherein the second substrate material comprises at least one of shredsof tobacco material, beads of tobacco material, an extruded structure oftobacco material, a crimped sheet of tobacco material, and combinationsthereof.
 18. The aerosol delivery device of claim 1, wherein thesubstrate material comprises at least one of a tobacco material and atobacco-derived material.
 19. The aerosol delivery device of claim 1,wherein the substrate material comprises a non-tobacco material.
 20. Theaerosol delivery device of claim 1, wherein the substrate materialcomprises at least one of shreds of tobacco material, beads of tobaccomaterial, an extruded structure of tobacco material, a crimped sheet oftobacco material, and combinations thereof.